EOLIOS Engineering White paper · CFD simulation for data centers
EOLIOS Engineering · Thermo-aeraulic consultancy Édition juillet 2026 · v1.0 eolios.fr
White paper · Data Center

CFD simulation for data centers

Density, aisles, plenums, dry coolers, fire, PUE: the entire thermo-aeraulic behaviour of a data center comes down to air flows. Method, standards and limits, in 21 chapters.

21 chapters4 parts≈ 55 min readGlossary, 44 terms
EOLIOS
EOLIOS Engineering · Data Center team
July 2026 edition · v1.0 · Public document, free to share
Online version: eolios.eu/data-center/white-paper-using-cfd-for-data-centers
How to read this document

Two readers, two routes

This white paper is written to be read in two ways. No content is held back: everything that follows is also published with free access on eolios.eu.

Decision-maker route · 10 minIn brief, then chapters 05, 18 and 21

The executive summary gives the ten structuring points. Chapter 05 explains how a room is scored objectively, chapter 18 the sequence and lead times of a study, chapter 21 the questions to ask a provider.

Engineer route · 55 minThe 21 chapters in order

Context and standards, then the physics and the simulation method, then what is actually simulated: site survey, nominal duty, failure scenarios, external CFD, fire and PUE.

In brief

CFD simulation reconstructs the air flows and temperatures of a data center rack by rack. It serves three purposes: proving that a design holds its intake temperatures, diagnosing existing hot spots, and testing failure scenarios with no operational risk. Its value does not come from the software, but from the scope selected, the boundary conditions and the validation against measurements.

  • Who uses it? Operators, owners and design offices, in design as well as in operation.
  • When? Before works to validate, after an incident to understand, before densification to decide.
  • What proof? Intake temperatures, RCI, RTI and Capture Index, under nominal duty and degraded scenarios.
Executive summary

Ten points to bear in mind before launching a study

This white paper addresses two readers. The decision-maker will find the essentials here in three minutes. The engineer will find, in the 21 chapters that follow, the physics, the assumptions, the metrics and the protocols: including what CFD cannot do.

  1. 01The thermal margin for error has collapsedDensity per rack has changed scale; sizing methods have not.
  2. 02Cooling capacity is almost never the shortageA data hall overheats through poor distribution of the available cooling, not through a lack of capacity.
  3. 03Two pathologies dominate all the othersHot air recirculation and cold air bypass: two airflow problems.
  4. 04Overcooling masks the symptomA low setpoint degrades PUE all year round without removing the risk.
  5. 05A room can be scored objectivelyRCI, RTI and Capture Index put figures on a before / after, beyond debate.
  6. 06CFD tests what operation cannot afford to testChiller loss, power cut, heatwave, fire: with no risk and no production stoppage.
  7. 07An unvalidated CFD is only a hypothesisMesh independence, residuals, closed balances, comparison with measurements.
  8. 08The envelope counts as much as the roomPlume recirculation on the roof feeds straight back into the chilled water temperature.
  9. 09Fire changes the criterionThe target is no longer comfort but tenability for evacuation and intervention.
  10. 10Value is measured in decisions, not in imagesIT capacity released, setpoint degrees recovered, risks removed.
415 TWhglobal electricity consumption of data centers in 2024, i.e. ≈ 1.5 % of the totalIEA · Energy and AI, 2025
945 TWh2030 projection in the base case, a doubling in six yearsIEA · Energy and AI, 2025
1.54global average PUE, unchanged for the sixth consecutive yearUptime Institute, 2025
1 in 8sites reporting racks in the 30–59 kW range; a few cabinets exceed 100 kWUptime Institute, 2025
Contents

The 21 chapters

IContext, physics of the problem and standards
  1. 01The thermal equation of digital: what has really changedContext
  2. 02From silicon to the atmosphere: the five scales of the thermal chainAnatomy
  3. 03The European regulatory framework: ASHRAE, EN 50600, Uptime, F-GasStandards
  4. 04The eight airflow pathologies of a data hallPathologies
  5. 05Engineering metrics: scoring a room objectivelyMetrics
  6. 06Overview of cooling technologies: from air to immersionTechnologies
IIThe physics and the simulation method
  1. 07What a CFD simulation actually computesFundamentals
  2. 08Physical modeling: turbulence, buoyancy, porous media, radiationModeling
  3. 09Meshing: the discretisation decides what will be seenMeshing
  4. 10Boundary conditions: where the reality of the site is injectedBoundary conditions
  5. 11Convergence, verification, validation, uncertaintiesV&V
IIIWhat is actually simulated on a data center
  1. 12The site survey: what is measured before simulatingSurvey
  2. 13Internal CFD of the data hall: what we look at, and in which orderInternal CFD
  3. 14Failure scenarios: the thermals of the first minutesFailures
  4. 15External CFD: dry coolers, plume recirculation, heatwave, heat islandExternal CFD
  5. 16Fire, smoke control and gas extinguishing: simulating the unacceptableFire
  6. 17PUE: where CFD really acts, and where it does notPUE
IVAssignment, lessons learned and limits
  1. 18How an assignment runs: deliverables, lead times, output formatAssignment
  2. 19Lessons from the field: what we have learned on siteLessons learned
  3. 20Classic mistakes observed in operationAnti-patterns
  4. 21Limits of CFD and questions to ask your providerLimits
I Part I

Context, physics of the problem and standards

What has changed in the rooms, what the standards say, and the engineering vocabulary needed to describe a pathology without ambiguity.

  1. 01The thermal equation of digital: what has really changedContext
  2. 02From silicon to the atmosphere: the five scales of the thermal chainAnatomy
  3. 03The European regulatory framework: ASHRAE, EN 50600, Uptime, F-GasStandards
  4. 04The eight airflow pathologies of a data hallPathologies
  5. 05Engineering metrics: scoring a room objectivelyMetrics
  6. 06Overview of cooling technologies: from air to immersionTechnologies
01
Context

The thermal equation of digital: what has really changed

Part I · Chapter 01

Almost all the electricity entering a data center leaves it as heat. The subject is therefore not "producing cold", but removing a thermal power that is increasingly concentrated in a volume which, for its part, has not grown.

Demand for digital infrastructure has changed order of magnitude. According to the International Energy Agency, data centers consumed around 415 TWh in 2024, close to 1.5 % of global electricity consumption, growing by about 12 % per year since 2017; the base case takes them to 945 TWh in 2030, a doubling in six years. That growth does not only mean more buildings: it means more watts per square metre of floor.

At 5 kW per rack, the volume of the room forgives approximations. At 40 kW, it forgives nothing: the same distribution error no longer costs one degree, but five.

Chapter 01 · the density effect

This is where the engineering break lies. A room designed around 5 kW per rack tolerates many approximations: the air volume of the room acts as a buffer, distribution errors are diluted, and a cooling failure leaves several tens of minutes of margin. At 15, 30 or 60 kW per rack, the same 10 % distribution error no longer produces one degree of deviation but five, the slightest hot air leak becomes a hot spot, and the time available before manufacturer thresholds are exceeded is counted in minutes, sometimes tens of seconds.

Field surveys confirm that the installed base is moving more slowly than the announcements: the Uptime Institute observes a continuous but slow rise in average densities, with growing adoption of the 10–30 kW range, one site in eight reporting racks between 30 and 59 kW, and a few cabinets beyond 100 kW still exceptional. This heterogeneity is precisely the problem: most operators today have to insert high-density islands into rooms designed for low, homogeneous density. It is the most frequent use case for CFD.

Did you know

The global PUE has stopped moving

The Uptime Institute measures an average PUE stuck around 1.54 for six consecutive years, while hyperscalers announce 1.10 to 1.15. The gap does not come from a technological secret: it comes from the quality of air distribution and from the ability to work with high setpoints in complete safety. That is exactly the playing field of simulation.

Concrete consequences of poorly controlled thermals

Classic methods, such as the global power balance, the "total airflow is sufficient" rule or the per-room load spreadsheet, answer a question of quantity. They never answer the question of location: where does the cold air actually arrive, at what temperature does it enter that specific rack, and what becomes of that distribution when one unit stops. Only a spatially resolved solution of the flows answers those three questions.

Optimizing the cooling of a data hall: temperature field computed over the whole volume

On eolios.eu Understanding how a data center works

02
Anatomy

From silicon to the atmosphere: the five scales of the thermal chain

Part I · Chapter 02

A frequent mistake is to treat the data center as a single object. In reality, the heat crosses five successive thermal barriers, each with its own physics, its own resistances and its own failure modes. A CFD study only makes sense if you know at which scale the question sits.

1mm
Component (chip, heat sink, cold plate)Conduction and interface resistances, local forced convection.
Tjunction · RthThrottling, degraded interface, fouling
2m
Server & rackInternal pressure drops and fan curves.
Rack ΔT · airflowInternal leaks, missing blanking panels, fans at their limit
310 m
Data hallMixed convection: supply jets against plume buoyancy.
Tintake · RCI · CIHot spots, recirculation, bypass, stratification
4building
Technical rooms & networksAir and water networks, plenums, UPS and switchgear rooms.
Network Δp · TroomsNetwork imbalance, overheating electrical room
5site
Envelope & siteWind, buoyancy of exhaust plumes, solar radiation.
Tfresh air · recirculationRecycling of hot exhaust, heatwave, heat island

The five successive thermal barriers, from the millimetre to the site: at each scale, one dominant physics, one critical quantity and one specific failure mode.

The scales are not independent: they propagate. Plume recirculation on the roof (scale 5) raises the air temperature at the dry cooler intakes, therefore the chilled water temperature, therefore the supply temperature in the room (scale 3), therefore the rack intake temperature (scale 2) and finally the junction temperature of the processors (scale 1). A defect at scale 5 is read at scale 1: and conversely, densification at scale 1 ends up visible on the roof.

Scale 3 · data hallComplete modeling of a data hallThe usable volume, the racks and the air handling units reconstructed in a single workable model.
Scale 4 · technical roomsThermals of a technical roomUPS and switchgear rooms: high density per square metre, small volume, a non-negligible share of radiation.
Model 3D interne d'un data hall : baies, allées et unités de traitement d'air
Internal 3D model: the data hall scale, where most of the air distribution is decided

This reading by scales also dictates the modeling scope. Simulating a whole room with heat sink detail would be absurd: the rack is represented by an equivalent model (airflow, ΔT, pressure drops). Conversely, studying an internal hot spot while modeling only the roof makes no sense. The right reflex is to choose the coarsest scale that still contains the cause of the problem, then go down one level if necessary.

On eolios.eu Thermal study of technical rooms (UPS, switchgear)

03
Standards

The European regulatory framework: ASHRAE, EN 50600, Uptime, F-Gas

Part I · Chapter 03

A thermal study only has value when related to an enforceable criterion. Without a reference framework, a temperature map is an aesthetic object; with one, it becomes proof of compliance or a record of deviation. Here are the texts that structure the practice.

Intake conditionsASHRAE TC 9.9

Classes A1 to A4. Defines the temperature and humidity envelope at the equipment intake, recommended range and allowable ranges.

Thermal compliance criterion
Design & operationEN 50600

European facility standard. Covers design, construction and operation, including availability classification and energy efficiency.

European regulatory framework
RedundancyUptime Tier I–IV

Topology and maintainability, not temperature. It does determine which degraded scenarios the study must demonstrate.

Defines the scenarios to simulate

ASHRAE TC 9.9: the reference for intake conditions

The Thermal Guidelines for Data Processing Environments from ASHRAE technical committee 9.9 define, for the air entering the equipment (and not for room air), a recommended range and allowable ranges per equipment class. The usual recommended range is 18 to 27 °C, with an upper relative humidity limit and a dew point envelope. The allowable ranges then extend by class: about 15–32 °C (A1), 10–35 °C (A2), 5–40 °C (A3) and 5–45 °C (A4). The committee has moreover extended its recommendations to liquid-cooled equipment to cover densities above 40 kW per rack, acknowledging that the historical air-centred framework was no longer sufficient.

Method note

The practical consequence of this framework is fundamental for simulation: the success criterion never bears on a room average, but on the air temperature at the intake of each rack, at every point of the usable height. A room averaging 22 °C can perfectly well show intakes at 34 °C at the top of a rack: that is a non-compliance, invisible in a global balance.

Editions and exact values evolve: for a project, always refer to the edition in force and to the manufacturer specifications of the installed equipment, which may be more restrictive.

EN 50600: the European facility standard

The EN 50600 series covers the design, construction and operation of data centre facilities and infrastructures: availability classes, physical protection, power distribution, environmental control and efficiency indicators (including PUE, also standardised at ISO/IEC level). It provides the contractual vocabulary that matters when a study has to prove a level of service, and not only thermal comfort.

Uptime Institute: the redundancy Tiers

The Tier I to Tier IV classification does not speak of temperature but of topology and maintainability. It concerns CFD directly because it defines the configurations to be proven: if the facility claims concurrent maintainability, then thermal behaviour must remain acceptable during the deliberate unavailability of a component. That is not demonstrated at nominal duty, but in a degraded scenario (chapter 14).

Environmental and safety framework: the European scale, the national variants

The structuring requirements are today European; it is their national transpositions that vary from one country to another. The same project run in France, Germany, the Netherlands or Ireland answers the same physical objectives, but before different authorities and permitting procedures.

On eolios.eu Cooling towers & environmental permitting Legionellosis & cooling towers

04
Pathologies

The eight airflow pathologies of a data hall

Part I · Chapter 04

In the field, thermal disorders almost always come down to a small number of recurring mechanisms. Naming them precisely is the first step of the diagnosis: each has a measurable signature and a distinct remedy. Confusing them leads to treating a symptom with the wrong lever: the textbook case being added cooling capacity to compensate for a sealing defect.

1 · Recirculation

Hot air rejected by the servers returns to the cold aisle and raises the intake temperature, generally at the top of the rack. Signature: strong vertical intake gradient, low machine ΔT.

  • Causes: missing blanking panels, unconfined aisle, insufficient airflow.

2 · Bypass

Cold air returns to the air handling unit without passing through any server. It cools nothing, but consumes fan energy and crushes the return ΔT.

  • Causes: badly placed perforated tiles, unbrushed cable openings, plenum leaks.

3 · Point chaud localisé

Zone where the intake exceeds the threshold while the room is globally cold. It is a distribution problem, never a capacity one.

  • Causes: dense island inserted, obstacle in the plenum, undersized grille.

4 · Déséquilibre de plénum

Under a raised floor, pressure is not uniform: some tiles supply air, others draw it in. A tile under negative pressure is a thermal short circuit.

  • Causes: insufficient height, cable trays, jet effect of the CRAC units.

5 · Stratification

In tall rooms or with low mixing, hot air accumulates under the ceiling and comes back down at the end of the aisle. The effect is amplified by buoyancy at high densities.

  • Causes: badly positioned high returns, global airflow too low.

6 · Surrefroidissement

The most common answer to the five previous pathologies: lower the setpoint. The hot spot recedes by a few degrees, the energy bill rises permanently.

  • Signature: low setpoint, low ΔT, degraded PUE, persistent hot spots.

7 · Interaction entre unités

Two neighbouring CRAH units fight over the return or blow against each other; the total airflow is met, the distribution is poor. Frequent after an extension.

  • Causes: unstudied layout, independent control loops.

8 · Discontinuité du confinement

A breached containment (open door, missing panel, removed rack) loses much of its benefit. Airflow is very sensitive to small openings.

  • Causes: operations, works, empty positions left unblanked.
Diagram of the origins of hot spots in a data center
Origins of hot spots: the cause is almost always a distribution, not a lack of capacity
CFD visualisation of hot air recirculation in a data center

These eight mechanisms combine, and that is what makes diagnosis difficult without simulation: the same temperature measured at the top of a rack may result from recirculation, from a bypass that has emptied the plenum, or from an interaction between two units ten metres away. The probes say that there is a problem; the computed field says where the air goes, therefore which remedy will work.

Pathology 1Recirculation effectsRejected hot air rises back into the cold aisle: the signature is a marked vertical gradient at the rack face.
Project · DC10Distribution of a real data hallMapping of supply and trajectories on one of our instrumented data halls.

On eolios.eu Origin of overheating in data centers

05
Metrics

Engineering metrics: scoring a room objectively

Part I · Chapter 05

To compare a before and an after, or two design variants, you need indicators that condense a three-dimensional field into a few numbers that can be discussed in a meeting. The industry has standardised a small set of them, all built on the same principle: comparing real thermals with ideal thermals.

Usual thermo-aeraulic performance metrics of a data hall. Target values are good-practice orders of magnitude, to be confirmed project by project.
IndicatorWhat it measuresReadingUsual target
RCIHI / RCILO
Rack Cooling Index
Share of intakes within the recommended ranges, weighted by the extent of the exceedances (high and low)100 % = no rack outside the recommended range> 96 %
RTI
Return Temperature Index
Ratio of the ΔT seen by the air handling units to the ΔT seen by the IT equipment< 100 % → bypass ; > 100 % → recirculation≈ 100 %
SHI / RHI
Supply / Return Heat Index
Fraction of heat picked up by the cold air before it reaches the serversLow SHI = little parasitic mixingSHI < 0.2
Capture Index (cold aisle)Fraction of the air drawn in by a rack that actually comes from the tiles or the containmentLocal indicator, rack by rack> 90 %
Capture Index (hot aisle)Fraction of the air rejected by a rack that is actually captured by the returnsThe remainder goes into recirculation> 90 %
Rack ΔTServer inlet/outlet difference, a direct image of the airflow passing throughLow ΔT = too much air or internal bypass10 to 20 K
Airflow ratioAirflow delivered by the distribution / airflow demanded by the servers< 1 → recirculation guaranteed1.05 to 1.15

The value of these indicators is twofold. In diagnosis, they point immediately to the right family of remedies: an RTI of 70 % with correct intakes signals excess airflow and bypass, therefore a saving potential, not a risk. In design, they make it possible to set performance commitments verifiable in the model, then at handover.

Airflow, the only truly sizing variable

Everything starts from an elementary enthalpy balance. The power removed by an air stream is written:

Enthalpy balance of air: the relation that sizes everything
Q̇ = ρ · cp · V̇ · ΔT
thermal power to be removed (W) · ρ air density (≈ 1.2 kg/m³) · cp specific heat capacity (≈ 1,006 J/kg·K) · volumetric airflow (m³/s) · ΔT temperature difference between return and supply (K)
thermal power removed (W) · ρ air density (≈ 1.15 kg/m³ at 30 °C) · cp specific heat (≈ 1,005 J/kg·K) · volumetric airflow (m³/s) · ΔT inlet/outlet temperature difference (K).
In practical form: V̇ [m³/h] ≈ 3,100 × P [kW] / ΔT [K], i.e. about 260 m³/h per kW for a ΔT of 12 K.

This relation explains most of the trade-offs of the trade. Increasing the ΔT proportionally reduces the airflow, therefore the fan energy (which varies roughly with the cube of the airflow): it is the most powerful saving lever. But a high ΔT means hotter return air, therefore far heavier consequences in the event of recirculation. Containment is not a comfort option: it is what makes a high ΔT usable without risk.

Containment is not a comfort option. It is the condition that makes a high ΔT, and therefore the energy saving, usable without taking a risk.

Chapter 05 · airflow, ΔT and fan energy

Working out an order of magnitude

The tool below applies this relation, then derives from it the second figure every operator should know: the rate of temperature rise of the room in the event of total loss of cooling, obtained by dividing the dissipated power by the thermal capacity of the air volume.

Worked example · 10 kW rack, ΔT of 12 K
V̇ = 3,100 × 10 / 12 ≈ 2,600 m³/h
That is about 260 m³/h per kW. For 40 identical racks, 104,000 m³/h to be distributed for 400 kW dissipated. In the event of a total loss of cooling, a data hall of 4,000 m³ then drifts by about +5 °C per minute (air only, excluding the inertia of masses).
Reading this drift is deliberately conservative: the thermal mass of the building, of the racks and of the servers typically slows the rise by 20 to 40 %, whereas unfavourable stratification can exceed thresholds locally well before the average. This order of magnitude does not replace a transient simulation (chapter 14), which alone gives the real evolution, rack by rack.
Online versionThe interactive calculator (power per rack, ΔT, number of racks, room volume) is available in the online version of this chapter: eolios.eu/data-center/white-paper-using-cfd-for-data-centers

On eolios.eu Guide to calculating the PUE of a data center

06
Technologies

Overview of cooling technologies: from air to immersion

Part I · Chapter 06

The choice of a cooling architecture is driven first by density per rack, then by site constraints (clear height, available water, climate, regulation) and finally by operations. CFD comes in at every level, but with different questions: in air, we look for where the air goes; in liquid, we look for what is left for the air to do, because part of the heat continues to be dissipated in the room.

Indicative fields of use. Density bounds are common-practice orders of magnitude, highly dependent on clear height, available plenum and climate.
ArchitectureUsual densityPrincipleCFD point of attention
Air, open room
raised floor + perimeter CRAC/CRAH
≤ 5–8 kWPressurised plenum, perforated tiles, free returnPlenum pressure uniformity, bypass, aisle length
Air + aisle containment
cold or hot
8–20 kWPhysical separation of flows; high usable ΔTSealing, blanking panels, doors, airflow ratio > 1
In-row / in-rack15–35 kWHeat exchanger as close as possible to the load, short loopInteraction between modules, control, local redundancy
Active rear door
rear-door heat exchanger
20–40 kWCapture at the rack outlet: the room stays neutralResidual room airflow, backup in the event of water loss
Direct liquid cooling (DLC)
cold plates
40–120 kW+The fluid captures 70 to 90 % of the heat at the componentResidual fraction dissipated to air, CDU, local hot spots
Dielectric immersion50–200 kWImmersed servers, single or two-phaseTank thermals, operation, fire and detection
Useful counter-intuition

Going liquid does not remove the air study

A rack under direct liquid cooling still rejects 10 to 30 % of its power into the room air: power supplies, memory, network, losses. On a 100 kW rack, that represents 10 to 30 kW of air to be handled, i.e. the density of a whole rack of the previous generation. Hybrid architectures are therefore the ones where CFD remains most useful, because nobody has any intuition about the residual thermals of a mixed room.

Coupled thermal analysis: data center and production plant, heat follows the same physics at every scale

Liquid cooling is progressing fast wherever accelerator loads demand it: some recent computing architectures reach cabinet powers of the order of 120 kW, out of reach of air cooling at full load. The installed base, however, remains overwhelmingly air cooled: the real challenge of the decade is less "air or liquid" than the coexistence of both in the same rooms, with different temperature ranges and different redundancies.

On eolios.eu Cooling systems for data centers Electronics cooling: from the component to the cold plate

II Part II

The physics and the simulation method

What a solver actually solves, which physical models are legitimate in a data hall, and under what conditions a result deserves to be believed.

  1. 07What a CFD simulation actually computesFundamentals
  2. 08Physical modeling: turbulence, buoyancy, porous media, radiationModeling
  3. 09Meshing: the discretisation decides what will be seenMeshing
  4. 10Boundary conditions: where the reality of the site is injectedBoundary conditions
  5. 11Convergence, verification, validation, uncertaintiesV&V
07
Fundamentals

What a CFD simulation actually computes

Part II · Chapter 07

CFD (Computational Fluid Dynamics) numerically solves the conservation equations of fluid mechanics over a domain divided into elementary volumes. It "predicts" nothing: it computes the consequences of the assumptions it is given. That is why the quality of a study rests first on the input data and on the choice of models.

The equations solved

In a data hall, air is treated as a weakly compressible Newtonian fluid. Three families of equations are solved simultaneously on each control volume: conservation of mass (continuity), conservation of momentum (Navier-Stokes, including the buoyancy term) and conservation of energy (enthalpy transport, with conduction and possibly radiation). To these are added, depending on the case, transport equations for turbulence, humidity, chemical species (smoke, extinguishing gas) or particles.

Conservation of momentum (Navier-Stokes)
∂(ρu)/∂t + ∇·(ρu⊗u) = −∇p + ∇·τ + ρg
ρ density · u velocity field · p pressure · τ viscous stress tensor · ρg gravity term, the driver of buoyancy
Momentum: the two right-hand terms that govern the thermals of a data hall are the pressure gradient (what the fans produce and what the tiles experience) and the gravity term coupled to density differences, the driver of hot plume buoyancy.

The solution is iterative: starting from an initial field, the solver corrects pressure and velocities until the local imbalances (the residuals) become negligible. A distinction is made between steady-state computations (seeking the equilibrium state, the nominal duty case) and transient ones (following the evolution in time), the latter being indispensable for a failure or a fire.

What CFD brings that no other method brings

Le champ complet

  • Temperature, velocity, pressure and age of air at every point, including where no probe could ever be placed.
  • Trajectories and stream tubes: you see where the air comes from before it enters a given rack.

Les scénarios extrêmes

  • Unit loss, power cut, heatwave, fire: testable with no operational risk.
  • Comparison of design variants before any commitment to works.

La causalité

  • Measurements record; computation explains and makes it possible to test a remedy in isolation.
  • Basis of a digital twin reusable at every change of load.
Internal CFD study of a data center: temperature field and air trajectories

On eolios.eu Dossier: what is CFD simulation?

08
Modeling

Physical modeling: turbulence, buoyancy, porous media, radiation

Part II · Chapter 08

A data hall is a case of mixed convection: supply jets impose a forced dynamic, while hot plumes impose a natural one. The two compete for the field, and depending on the balance of forces, the same room can behave very differently. The choice of models is therefore not a software detail: it is an engineering act that must be justified in the report.

Turbulence models

Turbulence is not solved directly: that would require meshes out of reach. Averaged equations (RANS) are solved and the effect of turbulence on the mean field is modeled.

Usual closure choices in data center studies.
ModelBehaviourTypical use
k-ε (standard, realizable)Robust and economical, but imprecise near walls and on separations; tends to over-diffuseLarge volumes, first iterations, low-density rooms
k-ω SSTGood compromise: reliable treatment of the boundary layer and of adverse gradientsDefault choice when wall temperatures and jets matter
RSM / anisotropic modelsMore expensive, captures complex recirculations betterSpecial cases, detailed expertise of one zone
LES / hybridResolves large unsteady structures; very high costResearch, strongly unsteady phenomena, local scale

Buoyancy: Boussinesq or variable density

At the moderate temperature differences of a data hall (10 to 20 K), the Boussinesq approximation (constant density except in the gravity term) is legitimate and numerically comfortable. It ceases to be so as soon as the differences become large: dry cooler plumes, generator exhausts, and of course fire, where density must be treated as fully variable with temperature. Using Boussinesq on a fire case is a classic modeling error.

Switching criterion: the Richardson numberRi = g · β · ΔT · L / u²

This dimensionless number compares the buoyancy forces (temperature difference, characteristic height) with the inertial forces of the supply (air velocity). It says which of the two drivers commands the flow.

Low Ri: the supply imposes its trajectory, the air goes where the designer sends it. High Ri (high density, low airflow, great height): buoyancy takes over and the air rises, whatever the design intent. That is the mechanism behind stratification and behind the majority of recirculations at the top of racks.

Porous media: representing without meshing

It would be absurd to mesh every tile perforation, every server and every grille. They are represented by equivalent porous media, characterised by a pressure drop law (viscous and inertial Darcy-Forchheimer terms) calibrated on manufacturer data or on measurements. This approach applies to perforated tiles (perforation ratio, presence of a damper), to rack faces, to filters and coils and to return grilles. The quality of that calibration directly determines the fidelity of the airflow distribution: it is often there, and not in the turbulence model, that accuracy is lost.

Modeling racks and air handling units

The software used in the data center world

The landscape splits into two families. On one side the data center dedicated tools, which embed object libraries (racks, CRAH, perforated tiles, containments) and directly compute the sector indicators. On the other the general-purpose solvers, heavier to deploy but with no limit of scope: this is the only possible choice as soon as a roof, a plume, a fire or an off-catalogue geometry has to be handled.

Data center dedicated6SigmaDCX / Cadence Reality DCThe sector's historical reference (formerly Future Facilities). Object library, built-in RCI, RTI and Capture Index post-processing, operations-oriented digital twin.Use: conventional data halls, capacity tracking, rack allocation.
General purposeAnsys Fluent & IcepakComplete finite-volume solver: mixed convection, radiation, transients, species. Icepak goes down to the scale of electronics and boards.Use: off-catalogue cases, degraded scenarios, component scale.
General purposeSiemens Simcenter, STAR-CCM+ and FloTHERMComplete chain from component to building, robust polyhedral meshing on cluttered industrial geometries.Use: technical rooms, dry coolers, thermal couplings.
Open sourceOpenFOAMFree, customisable solver, runnable without licence limits on massively parallel computing. Requires a genuine numerical culture.Use: large domains, external studies, bespoke developments.
FireFDS (NIST)Reference LES code for smoke and fire, backed by international validation protocols.Use: smoke control, tenability, gas extinguishing (chapter 16).
Cloud platformsOn-demand solversOff-site computing billed by usage, useful to parallelise a sweep of variants or setpoints.Use: parametric studies, computing load peaks.
What the software does not do

None of these tools decides the scope, the boundary conditions, the turbulence model or the compliance criterion: these are the four choices that make the value of the study, and they come before the solver. Two design offices using the same software can produce results several degrees apart. The question to ask a provider is therefore not "which software do you use?" but "how did you verify and validate this computation?" (chapter 11).

Radiation

Often negligible between racks, radiation becomes important again in three situations: compact technical rooms with high density per square metre (UPS, switchgear), solar gains on the envelope and roof in external studies, and fire, where it is a major transfer mode and governs spread to neighbouring racks.

On eolios.eu What is a data center digital twin?

09
Meshing

Meshing: the discretisation decides what will be seen

Part II · Chapter 09

Simulation amounts to solving a system of non-linear partial differential equations over a finite number of cells. The mesh is that division. It sets the spatial resolution of the information: a phenomenon smaller than the cell does not exist in the result. On a data hall, that means a coarse mesh will smooth out precisely what is being looked for: intake gradients at the top of racks and local leaks.

Meshing strategy for a data hall

Mesh independence, non-negotiable

A result only has value if it no longer depends significantly on mesh fineness. The demonstration is simple and must appear in the report: the same case is solved on at least three meshes of increasing fineness (typically a factor of 1.5 to 2 on the characteristic size) and a few representative output quantities are tracked: maximum intake temperature, RCI, airflow of a critical tile. When the difference between two levels drops below a threshold (often a few tenths of a degree), the mesh is deemed sufficient.

Example of mesh and refinement level
Example of a hybrid mesh and successive refinement levels
Order of magnitude

A data hall of common size is routinely modeled with a few million to a few tens of millions of cells depending on the level of detail of the racks and the plenum. Quality does not come from the number of cells, but from their placement: ten million badly distributed cells are worth less than two million well oriented towards the useful gradients.

Stream tubes coloured by temperature: the trajectory of the air, information no probe provides
10
Boundary conditions

Boundary conditions: where the reality of the site is injected

Part II · Chapter 10

Boundary conditions mathematically express the interaction between the computed domain and its environment. They carry most of the physical truth of the site: it is through them that the simulation learns what the installation really does. Formally, either a value is imposed on the boundary (Dirichlet condition: temperature, velocity), or a flux or gradient (Neumann condition: dissipated power, adiabatic wall), or a mixed relation (heat transfer coefficient, fan curve).

Boundary conditions of a data hall study and their associated pitfalls.
BoundaryCondition appliedFrequent pitfall
CRAH supplyAirflow-pressure curve, supply temperature, jet direction and diffusionFixed airflow and purely normal jet: reality includes a swirl component and a control range
ReturnImposed pressure or balanced extracted airflowIdealised return that "sucks up everything", masking the real recirculation
Perforated tilesCalibrated porous medium + damper if anyNominal perforation ratio ≠ real permeability with a partly closed damper
RacksDissipated power + airflow or ΔT, internal pressure dropsNameplate power instead of the power actually consumed: massive overestimation
Walls, ceiling, floorAdiabatic, isothermal or heat transfer coefficient; solar gains where relevantSetting everything adiabatic: acceptable in a data hall, wrong in a technical room on a façade
Leaks & openingsEquivalent leakage areas, containment doorsComplete omission: the model becomes better performing than the real room
Fresh air / outdoorsTemperature, humidity, wind (atmospheric boundary layer profile)Using an annual average instead of the sizing climatic scenarios

The choice of climatic scenarios deserves particular attention. An installation is sized on unfavourable situations: high-percentile heatwave (not a monthly average), wind direction penalising for plume recirculation, winter for condensation and free cooling questions. In practice, a reduced set of sizing operating points is retained, each justified by climatic data from the most representative weather station.

Rule of thumb

The accuracy of a CFD is capped by the worst of its input data

An IT power known to ±30 % makes any debate about the turbulence model illusory. Before refining the computation, you have to refine the inputs: powers actually measured, airflows surveyed, positions recorded. That is the purpose of the site survey (chapter 12).

11
V&V

Convergence, verification, validation, uncertainties

Part II · Chapter 11

A simulation always produces images. Nothing guarantees that they describe anything. The distinction is structuring: verification asks "are we solving the equations correctly?", validation asks "are we solving the right equations, with the right data?". Both are necessary and neither replaces the other.

Convergence criteria

Residuals

Stabilised several orders of magnitude below their initial value: a necessary condition, never a sufficient one.

Closed balances

Mass and energy conserved over the domain to within 1 %. A balance that does not close invalidates the computation, even with fine residuals.

Steadiness of the quantities of interest

The maximum intake temperature and the critical airflows no longer evolve with the iterations.

No parasitic physical instability

A real room may be intrinsically unsteady (oscillating plumes); the case must then be run as a transient rather than forcing a false convergence.

Validation: confronting reality

On an existing installation, validation consists in comparing the computation with independent measurements: intake temperatures recorded at several heights, tile airflows, return temperatures, possibly smoke tests to check trajectories qualitatively. The least well known parameters are then adjusted (permeabilities, leaks, real distribution of powers) until an acceptable agreement is reached. That is calibration. It turns a generic model into a digital twin of the site, reusable for all subsequent studies.

An honest limit

On a new-build project, no direct validation is possible: there is nothing to measure. Confidence then rests on three pillars: models validated on analogous cases, explicitly stated conservative assumptions, and a sensitivity analysis on the uncertain parameters. A serious report says which ones, and in which direction they push the result.

Sensitivity analysis and margins

Rather than a single figure, a robust study delivers a range. The doubtful parameters are varied within their credible bounds (IT power ±10 %, plenum leaks, damper opening ratios, outdoor temperature) and the effect on the indicators is observed. This answers the only question that really counts in a project meeting: how much margin do we have before the conclusion changes?

III Part III

What is actually simulated on a data center

From the site survey to failure scenarios, from the room to the roof, from fire to PUE: the six families of studies we carry out.

  1. 12The site survey: what is measured before simulatingSurvey
  2. 13Internal CFD of the data hall: what we look at, and in which orderInternal CFD
  3. 14Failure scenarios: the thermals of the first minutesFailures
  4. 15External CFD: dry coolers, plume recirculation, heatwave, heat islandExternal CFD
  5. 16Fire, smoke control and gas extinguishing: simulating the unacceptableFire
  6. 17PUE: where CFD really acts, and where it does notPUE
12
Survey

The site survey: what is measured before simulating

Part III · Chapter 12

On an existing installation, the most profitable phase of a study is not the computation: it is the measurement campaign. It sets the upper bound of accuracy for everything that follows, and on its own it reveals part of the disorders.

The minimum data set

Identification of hot spots by CFD simulation after calibration on survey data
Consistency above all

The first check to run on a set of measurements is a power balance: the heat removed by the units (airflow × return ΔT) must match, to within a few percent, the electrical power consumed by the IT equipment. When the gap exceeds 15 %, it is not the room that is strange: it is a measurement that is wrong. Detecting that before modeling saves weeks of analysing an artefact.

Qualitative validationSmoke test on a load bankSmoke makes trajectories visible: it is the most convincing tool for confronting a computation with reality.
After calibrationThe digital twin of the siteOnce tuned on measurements, the model becomes reusable at every change of load.
Seen on site

The most instructive discrepancy of a measurement campaign is almost never thermal: it is a documentary one. Real powers per rack that do not match the file, blanking panels removed during an intervention and never put back, perforated tiles moved over the years without updating the drawing. The model first serves to make those discrepancies visible, before computing anything at all.

On eolios.eu Data center audit & diagnostics

13
Internal CFD

Internal CFD of the data hall: what we look at, and in which order

Part III · Chapter 13

At nominal duty, the objective is not to produce a beautiful map but to answer a finite list of questions, in an order that goes from the global to the local. This sequence is our standard analysis grid.

Analysis grid of an internal CFD, from the global balance to the local diagnosis.
#Question askedResult usedAssociated decision
1Is the total airflow sufficient, and with what margin?Airflow ratio, RTIAdjust fan speed, reveal a costly excess
2Is the under-floor distribution homogeneous?Plenum pressure field, tile-by-tile airflowMove tiles, blank off, clear the plenum
3What air temperature actually enters each rack?Vertical intake profiles, RCI, Capture IndexASHRAE compliance, placement of dense loads
4Where does the air entering the critical racks come from?Trajectories, age of air, stream tubesDistinguish recirculation, bypass and plenum defect
5Is the containment effective?Leakage airflows at the interfaces, temperature isovaluesRework the sealing, blank off empty positions
6How far can the setpoint be raised?Setpoint sweep, margin at the most critical thresholdDirect PUE gain, extension of free cooling
7Where should the next dense racks go?Mapping of residual capacity per locationLayout plan, IT capacity released

The sixth question is the one that produces the most economic value, and it is the one that cannot be asked without simulation. Raising the supply setpoint by 2 to 3 °C reduces cooling production consumption and considerably extends the annual hours of free cooling: but only if there is proof that no rack leaves its allowable range, including at the top of the worst-placed rack, including when one unit is stopped. CFD provides exactly that proof.

Temperature plane before optimization
Temperature plane after optimization
Before / after optimization: same installed power, corrected distribution
Project · rooms 5 & 6Two data halls in parallelComparison of two neighbouring rooms: same design, different airflow behaviour.
ASHRAE criterionInlet temperatures, rack by rackThe only criterion that counts: the air at the intake, over the whole usable height, not the room average.

Technical rooms, a classic blind spot

Server rooms concentrate attention; UPS, switchgear and transformer rooms concentrate incidents. They combine high density per square metre, a small volume, often rudimentary ventilation, a share of radiative transfer and strict manufacturer thresholds on batteries. They are excellent candidates for a dedicated study, generally quick and with a high return.

On eolios.eu Data center CFD engineering Technical rooms

14
Failures

Failure scenarios: the thermals of the first minutes

Part III · Chapter 14

A well-designed data center is not judged at nominal duty, where almost everything works, but on its ability to get through an incident. This is the field where CFD has no competitor: nobody agrees to shut down a chiller in production to see what happens.

The scenarios to be investigated

Simulation transitoireTotal loss of cooling: how much time is available?Data hall of 4,000 m³, air only. The inertia of the building and of the equipment slows the rise by 20 to 40 %. Conversely, unfavourable stratification makes a threshold be exceeded locally well before the average.
Low density200 kW≈ 2.5 °C per minute
+10 °C threshold reached in ≈ 4 min≈ 5 min with real inertia
Common density400 kW≈ 5 °C per minute
+10 °C threshold reached in ≈ 2 min≈ 2.6 min with real inertia
High density800 kW≈ 10 °C per minute
+10 °C threshold reached in ≈ 1 min≈ 1.3 min with real inertia

At 200 kW in a large volume, the operator has time to react. At 800 kW, the automatic fan restart sequence becomes the only safeguard: its response time must be compared with the time to threshold exceedance, rack by rack.

These orders of magnitude are enough to understand why the subject has changed nature with density: at 200 kW in a large volume, the operator has time to react; at 800 kW, the automatic fan restart sequence becomes the only safeguard, and its response time must be compared with the time to threshold exceedance. That is precisely what a transient simulation provides: not an average, but the intake temperature curve of each rack, second by second.

A data center is not judged at nominal duty, where almost everything works. It is judged on the first two minutes of an incident.

Chapter 14 · failure scenarios
Transient simulation: evolution of temperatures over time after an incident
Perverse effect of containment

An effective containment reduces the buffer volume

Aisle containment is excellent at nominal duty: it removes mixing. But in the event of a loss of cooling, it isolates the load within a reduced air volume: the hot aisle no longer has the inertia of the whole room to damp the rise. The best rooms in operation may therefore be the fastest to drift: a counter-intuitive result that only a transient simulation brings out.

15
External CFD

External CFD: dry coolers, plume recirculation, heatwave, heat island

Part III · Chapter 15

The whole cooling chain depends on a single physical quantity: the temperature of the air actually drawn in by the outdoor heat exchangers. And that temperature is not the one from the weather station. It results from the interaction between the hot exhausts of the installation, the geometry of the roof and of the site, and the wind. That is the object of external CFD.

Plume recirculation, the central mechanism

Definition · Plume recirculation (external recirculation)

Re-ingestion, by a dry cooler or a generator set, of all or part of the hot air it has just rejected: directly or after reflection on an obstacle, a parapet or an acoustic enclosure. The result is a rise in the inlet air temperature that degrades the available cooling capacity at the very moment when it is most needed.

Plume recirculation is a self-aggravating mechanism: the machine whose inlet air heats up sees its performance fall, draws more power, therefore rejects more heat, and feeds its own plume. The at-risk configurations are well identified: machines too close together, exhausts directed towards a neighbouring intake, high parapets trapping hot air, badly sized acoustic enclosures, and neighbouring buildings creating a wake that pushes the plumes back down onto the roof.

Heat rejection of rooftop systems: the hot plume drawn by computation, before it returns to the intake

The questions handled externally

Plume recirculation without acoustic enclosure
Plume recirculation with acoustic enclosure
Effect of an acoustic enclosure on the recirculation between generator sets and dry coolers
Heat rejectionRooftop plumes, second variantSame roof, different layout: the path of the plume completely changes the intake temperature.
OptimizationOptimization of thermal plumesDischarge height, orientation, screens: every degree gained at the intake is found again in the cooling production.

The link with the internal study is direct and quantifiable: every degree gained at the machine intakes translates into available cooling capacity, therefore chilled water temperature, therefore margin on the supply setpoint. That is why we increasingly handle both scopes in a single coupled assignment, rather than as separate studies.

Heat islandCampus of 24 data centersLarge-scale study: the cumulated heat rejection of a whole campus and its effect on the ambient air.
Wind & siteExternal wind studyThe wake of neighbouring buildings pushes plumes back down: the wind decides the temperature seen by the machines.

Plume recirculation on a roof does not stay on the roof. It works its way back into the chilled water, into the supply setpoint, and ends up on the face of the worst-placed rack.

Chapter 15 · propagation between scales

On eolios.eu External CFD simulation of a data center Heat island impact

16
Fire

Fire, smoke control and gas extinguishing: simulating the unacceptable

Part III · Chapter 16

The fire risk of a data center has its own characteristics: a high concentration of electrical energy, combustibles producing dense, toxic and corrosive smoke, and a stake that is not only human but also material: combustion products attack electronics far beyond the burned zone. Simulation changes objective here: we no longer look for comfort, we look for tenability and control.

What is computed

Fire study: temperature plane at 1.50 m in a data hall, scenario with spread

Two modeling requirements set fire apart from the rest: the computation is necessarily transient, over durations of several tens of minutes, and density must be treated as fully variable: the Boussinesq approximation has no validity left with differences of several hundred degrees. Radiation becomes a first-order transfer mode, and the definition of the design fire (power, growth curve, area, soot production) must be justified against the applicable framework.

Smoke controlIsosurfaces of fresh and hot airThe stratification that smoke control seeks to establish: and that comfort ventilation can destroy.
Gas extinguishingDispersion of NOVEC agentHomogeneity of concentration and hold time: the two criteria of an effective gas extinguishing system.

On eolios.eu Data center fire simulation Automatic gas extinguishing systems

17
PUE

PUE: where CFD really acts, and where it does not

Part III · Chapter 17

PUE relates the total energy of the site to the useful energy of the IT equipment. It is simple, imperfect, universally used. And it is stagnating: 1.54 as a global average, unchanged for six consecutive years according to the Uptime Institute, against 1.10 to 1.15 claimed by hyperscalers and 1.58 to 1.80 observed in colocation and enterprise. The gap is not technological: it is aeraulic and operational.

Definition of Power Usage Effectiveness
PUE = Etotal site / EIT
Etotal site energy entering the site over the measurement period · EIT energy consumed by the IT equipment alone · a PUE of 1.5 means 0.5 kWh of infrastructure per useful kWh
A PUE of 1.54 means that 54 % of the IT energy is added as overhead: cooling production, ventilation, electrical distribution losses, lighting. The cooling share makes up most of it: and it is the only one an airflow study can act on.

The five levers simulation acts on

Improvement levers accessible through an airflow study. Gains depend entirely on the initial state: an already optimized room offers no potential.
LeverMechanismCondition to be proven
Raise the supply setpointBetter cooling production efficiency, more free cooling hoursNo rack intake outside the range, including in degraded mode
Reduce the ventilation airflowFan power varies roughly as the cube of the airflowAirflow ratio kept > 1, no induced recirculation
Increase the ΔTLess airflow for the same power, better heat exchangeSealed containment, otherwise the hot return feeds the hot spots
Remove the bypassThe cold air produced finally serves to cool; the return ΔT risesLocate the leaks: tiles, brushes, plenum
Stop redundant unitsRun with fewer units but better distributedAcceptable behaviour in the event of the loss of a remaining unit

The global PUE is not stuck at 1.54 for lack of technology. It is stuck because nobody dares raise a setpoint without proof.

Chapter 17 · the real potential

Conversely, one has to be clear about what CFD does not do: it improves neither the efficiency of a chiller, nor that of a UPS, nor the load factor of the IT equipment. A PUE degraded by a very low load factor is not corrected by an airflow study: it is corrected by consolidation. Knowing how to tell the two situations apart avoids selling, and buying, the wrong study.

On eolios.eu Guide to calculating PUE Energy optimization & PUE

IV Part IV

Assignment, lessons learned and limits

How a study runs, what ten years of assignments have taught us, and the questions to ask before signing.

  1. 18How an assignment runs: deliverables, lead times, output formatAssignment
  2. 19Lessons from the field: what we have learned on siteLessons learned
  3. 20Classic mistakes observed in operationAnti-patterns
  4. 21Limits of CFD and questions to ask your providerLimits
18
Assignment

How an assignment runs: deliverables, lead times, output format

Part IV · Chapter 18

Our reference commitment on a data hall is four weeks, from scoping to presentation: and we know how to go faster when the project schedule demands it.

A CFD study is not an isolated computation but a sequence of decisions shared with the design team and the operator. The sequence below is the one we apply: one calendar month, with phases partly run in parallel. Our in-house computing resources make it possible to compress that lead time to two or three weeks in an accelerated procedure: a commissioning trade-off, an urgent layout decision, an incident to investigate. Only two situations really extend it: a very large number of transient scenarios, and waiting for input data on the operator's side.

Jours 1–3

Scoping & data collection

Precise definition of the questions the study has to answer, of the compliance criteria retained and of the list of scenarios. Collection of drawings, technical data sheets, BMS records and real powers.

Assumptions noteList of scenariosList of missing data
Week 1

Site survey (existing facility)

Measurement campaign on site, in one to two days of intervention: intakes, tile airflows, pressures, thermography, smoke test where useful. Power consistency check carried out immediately afterwards.

Measurement reportRecord of deviations from the file
Week 1–2

Modeling & meshing

Construction of the workable 3D model: useful geometry, calibrated porous media, boundary conditions. Hybrid mesh, refinement of gradient zones, independence study.

3D modelJustification of the mesh
Week 2–3

Calibration on measurements

On an existing installation: adjustment of the poorly known parameters until agreement with the survey. The model becomes the digital twin of the site: it is the deliverable that outlives the study.

Calibration reportComputation / measurement deviations
Week 3

Scenarios & iterations

Computation of the nominal duty then of the degraded scenarios, launched in parallel on our computing resources. Testing of the proposed remedies, one by one, to isolate the effect of each.

Set of scenariosQuantified comparison of variants
Week 4

Analysis & presentation

Maps, sections, trajectories, animations, indicators (RCI, RTI, CI) and an action plan ranked by effect/cost ratio. Technical presentation meeting with the operations teams.

Study reportPrioritised action planAnimations & visualsInteractive 3D model
Ensuite

Life of the model in operation

The digital twin stays available: every densification, every rack move or setpoint change is tested on the existing model in a few days, without starting from scratch. That is what turns CFD from a project deliverable into an operations tool.

Load updatesLayout testsModel picked up again at each phase
19
Lessons learned

Lessons from the field: what we have learned on site

Part IV · Chapter 19

Six assignments, six different mechanisms. The detailed case files, with configurations and results, are published on this site.

Data halls DC10 · DC17 · DC25

Series of internal studies on rooms with evolving load: under-floor distribution, recirculation effects and behaviour as load ramps up. Recurring lesson: the announced capacity of a room is almost always limited by its worst rack, not by its average.

  • DC10: internal
  • DC17: internal
  • DC25: internal

Data center hyperscale · interne + externe

Coupled envelope and room study on a high-density site: internal performance could not be guaranteed without first dealing with the behaviour of the rooftop heat rejection. A direct illustration of the propagation between scales of chapter 02.

  • External & internal CFD, hyperscale

Technical rooms & UPS (Italie)

Data hall and UPS rooms handled together. Electrical rooms, often outside the scope of studies, frequently turn out to be more constrained than the server room itself.

  • Data hall & UPS rooms, Italy

Dry coolers in a heatwave

Critical study of the behaviour during a heatwave episode: identification of heat accumulations and of plume recirculation on the rooftop machines, with a direct effect on the available cooling capacity.

  • Dry coolers: critical heatwave study

Commissioning & bancs de charge

Modeling of the testing phase: load banks reproduce neither the geometry nor the flow distribution of the real IT equipment. A successful handover therefore does not prove healthy operation: unless the discrepancy has been simulated.

  • Commissioning: load banks

Désenfumage de data hall

Fire scenarios contained to one rack then with spread: compartmentation and channelling of the flows determine tenability for responders far more than raw extraction airflow.

  • Smoke control engineering
Project · DC25Plume synthesis, 27 °CBehaviour of the heat rejection at a high setpoint: the case where the usable limit is being sought.
Project · hyperscaleExternal study of a hyperscale siteEnvelope and roof of a high-density site, handled together with the room in a single assignment.
Project · ItalyData hall & UPS roomsElectrical rooms often turn out to be more constrained than the server room itself.
Project · backupPressure drops of a generator setEnclosures, grilles and louvres: what the silencer really costs in airflow terms.

On eolios.eu All our data center projects

20
Anti-patterns

Classic mistakes observed in operation

Part IV · Chapter 20

These situations come back on almost every site we audit. None of them stems from a sophisticated engineering error: they are operational drifts or design shortcuts, with a disproportionate thermal effect.

Lowering the setpoint to treat a hot spot

The hot spot recedes by a few degrees, the bill rises all year round and the aeraulic cause remains intact. At the next load addition, the problem comes back: with less margin than before.

identify the mechanism (recirculation, bypass, plenum) before touching the setpoint
Empty rack positions left unblanked

Every free U left unblanked is a direct short circuit between hot aisle and cold aisle. The cumulated effect over a row often exceeds that of a whole cooling unit.

systematic blanking panels, including on partly filled racks
Perforated tiles laid "as close as possible" to hot racks

Adding tiles right next to a dense rack lowers the local plenum pressure and can degrade the airflow of neighbouring tiles, or even reverse some of them.

check the plenum pressure field before adding any tile
Cable trays accumulated in the plenum

The under-floor plenum is an air distribution network, not a storage space. Historical layers of cable create obstacles that starve whole zones of air, often far from the point of accumulation.

map the obstructions, clear the main axes, remove abandoned cables
Unbrushed cable openings

A floor cut-out with no brush grommet lets a significant flow of cold air escape, outside any rack. It is the cheapest bypass to correct and the most frequently ignored.

brushes or seals on all openings, including in the hot aisle
All cooling units running at full power "to be safe"

Running every unit, redundant ones included, at maximum speed strongly increases fan consumption (which varies roughly as the cube of the airflow) and creates jet interference that degrades distribution instead of improving it. The safety being sought is illusory: it is never demonstrated on the unit-loss scenario, the only case where it would count.

test the reduced configurations in simulation, then replay them on the digital twin at every change of load
Densifying without requalifying the room

Inserting a GPU island into a room designed for low homogeneous density produces an instantaneous hot spot, whatever the total cooling capacity available.

prior aeraulic requalification and choice of location through residual capacity mapping
The study filed away in a drawer

The most expensive case of all: a study delivered, read, applied, then forgotten. Six months later, the room has changed load and nobody knows whether the conclusions still hold. Yet the model existed, calibrated and ready to replay the case in a few days.

keep the digital twin alive: update it at every densification and test the layout before every rack delivery
Containment breached after works

Panel not put back, door blocked open, rack removed without blanking: the containment loses much of its benefit, with no alarm and no trace.

reinstatement checklist after every intervention, periodic thermographic check
Seen on site

In a presentation meeting, the question asked is practically never "where are the hot spots?": operations already know them. It is "what can I do on Monday, without stopping production?". That is why the action plan is ranked by effect/cost ratio, and why the remedies are tested one by one in the model: so that we can say which one is sufficient on its own.

21
Limits

Limits of CFD and questions to ask your provider

Part IV · Chapter 21

An honest white paper must say where the tool it presents stops. CFD is powerful; it is also easy to misuse, and a wrong result is visually indistinguishable from a right one.

What CFD cannot do

Eight questions to ask before ordering a study

01
Objectif

Which output quantities and which compliance criteria will be delivered, and against which framework?

02
Physique

Which turbulence model is selected, and why that one?

03
Numérique

Will mesh independence be demonstrated in the report?

04
Numérique

Will the mass and energy balances be provided?

05
Validation

On which measurements will the model be calibrated, and which computation/measurement deviations are considered acceptable?

06
Modeling

How are the fans (curve or fixed airflow) and the leaks represented?

07
Scénarios

Which degraded scenarios are included, steady-state or transient?

08
Livrable

Will the model be delivered and reusable for future changes, or is the study a dead deliverable?

A data center to design, make reliable or optimize?

Internal and external CFD studies, failure scenarios, PUE, fire safety: our engineers work alongside you from design to operation.

Talk to an engineer
Appendix A

Frequently asked questions

Appendix A · FAQ

What is a CFD study used for in a data center?

It numerically reconstructs the air flows and temperatures of a data hall to check that each rack receives air at the target intake temperature, including in a degraded configuration. Concretely, it serves to validate a design before works, to diagnose existing hot spots, to test failure scenarios with no operational risk and to release IT capacity without heavy investment.

What is the maximum density that can be cooled by air?

With air alone, with aisle containment and a correctly sized plenum, the practical limit generally lies between 15 and 25 kW per rack. Between 25 and 40 kW, in-row or active rear-door architectures become necessary. Beyond 40 to 50 kW, direct liquid cooling becomes the only realistic route: ASHRAE has moreover extended its recommendations to liquid-cooled equipment for those densities.

How many m³/h of air are needed to cool a rack?

About 3,100 m³/h per kW dissipated, divided by the temperature difference across the rack. For a 10 kW rack with a ΔT of 12 K: about 2,600 m³/h, i.e. roughly 260 m³/h per kW. A higher ΔT reduces the airflow and the fan energy, but makes containment and aisle sealing far more critical.

What is the difference between internal and external CFD?

Internal CFD deals with the data hall and the technical rooms: air distribution, hot spots, recirculation, containment, failure scenarios, fire. External CFD deals with the envelope and the roof: intake and discharge of the dry coolers, plume recirculation, interaction with wind and neighbouring buildings, heatwave, heat island.

The two answer each other: an outdoor air temperature degraded by plume recirculation feeds straight back into the performance of the cooling production, and therefore into the room.

How long does a data center CFD study take?

Our reference sequence fits into one month: a few days of scoping and data collection, one week including the site survey, one week of modeling and meshing, one week of computations and iterations on the scenarios, then one week of analysis and presentation. In an accelerated procedure, we go down to two or three weeks. Only a very large number of transient scenarios or an extended internal/external coupling calls for more computing time.

Is a CFD simulation reliable?

It is reliable if it is verified and validated: mesh independence demonstrated, residuals converged, energy and mass balances closed, and comparison with field measurements when the installation exists. An unvalidated CFD remains a hypothesis, not a result: and nothing, visually, distinguishes the two.

Can CFD reduce PUE?

Indirectly but genuinely. It does not act on machine efficiency: it acts on the aeraulic potential, raising the setpoint without exceeding the limits at the racks, removing overcooling, reducing the ventilation airflow, increasing the ΔT, extending free cooling. Those are the items that weigh most in the cooling share of PUE, whose global average has been stuck around 1.54 for six years.

Can a CFD be run on a new-build project, without measurements?

Yes, and it is even the most frequent case in design. Confidence then rests on models validated on analogous cases, explicitly stated conservative assumptions and a sensitivity analysis on the uncertain parameters. At commissioning, a measurement campaign makes it possible to tune the model and turn it into the digital twin of the site for its whole lifetime.

Appendix B

Sources & standards

Appendix B · Sources

The market data quoted in this white paper come from public, dated and verifiable sources. Technical standards must always be consulted in their edition in force: the values reproduced here are indicative.

  1. 01International Energy Agency (IEA), Energy and AI, World Energy Outlook Special Report, April 2025: 415 TWh consumed by data centers in 2024 (≈ 1.5 % of global electricity), growth ≈ 12 %/year since 2017, projection ≈ 945 TWh in 2030 in the base case. iea.org
  2. 02Uptime Institute, Global Data Center Survey 2025 (15th edition), July 2025: global average PUE ≈ 1.54, stable for the sixth consecutive year; rising densities in the 10–30 kW range, one site in eight reporting racks of 30 to 59 kW. uptimeinstitute.com
  3. 03ASHRAE Technical Committee 9.9, Thermal Guidelines for Data Processing Environments: recommended and allowable intake air ranges, classes A1 to A4, extension to liquid-cooled equipment for high densities.
  4. 04EN 50600 series (and ISO/IEC 22237): design, construction and operation of data centre facilities and infrastructures; energy efficiency indicators.
  5. 05Uptime Institute, Tier Standard: Topology & Operational Sustainability: Tier I to IV classification, concurrent maintainability and fault tolerance.
  6. 06Lawrence Berkeley National Laboratory, 2024 report on the electricity consumption of US data centers: 176 TWh in 2023, projection of 325 to 580 TWh by 2028.
  7. 07European regulatory framework: nomenclature of installations classified for environmental protection (ICPE) applicable to generator sets, refrigerants and cooling towers; European F-Gas regulation on fluorinated greenhouse gases.
  8. 08EOLIOS technical publications: all the dossiers and project sheets quoted in this white paper are accessible from our Data Center resources.

2026 edition of the EOLIOS white paper. The engineering orders of magnitude given in the tables (density ranges, indicator targets, assignment durations) reflect our practice and do not constitute normative values: every project must be checked in its own context.

Appendix C · Glossary

The 44 terms used in this document

The terms are also defined in the margin of the text, where they are used, in the online version.

Age of airTime elapsed since a particle of air entered the domain. Reveals poorly swept zones.
ASHRAE TC 9.9Technical committee publishing the reference thermal guidelines for information technology environments.
Blanking panelPanel closing an empty position at the rack face, to prevent the short circuit between aisles.
Boussinesq approximationAssumption treating density as constant except in the gravity term. Valid at small temperature differences, invalid in fire.
BypassCold air returning to the air handling unit without having passed through any IT equipment. Cost without benefit.
Capture Index (CI)Fraction of the air drawn in by a rack that actually comes from the cold distribution (or fraction of its discharge actually captured).
CDUCoolant Distribution Unit: hydraulic interface between the building loop and the liquid cooling loop of the racks.
CFDComputational Fluid Dynamics: numerical solution of the equations of fluid mechanics on a discretised domain.
Cold aisle / hot aisleArrangement of racks back to back and face to face, so that all intakes open onto the same aisle and all discharges onto the other.
ContainmentPhysical separation of the hot and cold aisles, the condition for operating a high ΔT.
CRAC / CRAHComputer room air handling units, with direct expansion (CRAC) or with a water coil (CRAH).
Darcy-ForchheimerPressure drop law of a porous medium, combining a viscous (linear) term and an inertial (quadratic) term.
ΔT (delta T)Temperature difference, generally between the inlet and the outlet of a rack or of an air handling unit.
Design fireStandardised description of a computed fire: power, growth curve, area, smoke production.
DLCDirect Liquid Cooling: liquid cooling in contact with the component through a cold plate.
EN 50600Series of European standards covering the design, construction and operation of data centre facilities.
Free coolingCooling production using outdoor conditions directly, without (or with little) mechanical compression.
Gaseous extinguishing systemAutomatic gas extinguishing installation, the usual fire protection mode of server rooms.
Hot spotLocalised zone where the intake temperature exceeds the allowable threshold, regardless of the room average.
ImmersionCooling by immersing the servers in a dielectric fluid, single or two-phase.
In-rowCooling unit inserted in the row of racks, as close as possible to the thermal load.
k-ε / k-ω SSTTurbulence closure models in the RANS approach. The second handles boundary layers and adverse gradients better.
LESLarge Eddy Simulation: explicit resolution of the large turbulent structures, very high computing cost.
Mesh independenceDemonstration that the result no longer evolves significantly when the mesh is refined.
Mixed convectionRegime where forced dynamics (fans) and natural dynamics (buoyancy) are of comparable importance. The typical data hall case.
Perforated tileRaised floor tile with an open area allowing air to pass from the plenum into the cold aisle.
PlenumAir distribution volume, generally under the raised floor, pressurised by the air handling units.
Plume recirculationRe-ingestion by a machine of the hot air it has just rejected. A self-aggravating mechanism on rooftops.
Porous mediumEquivalent representation of a permeable object (tile, filter, rack face) by a pressure drop law, without meshing its fine geometry.
PUEPower Usage Effectiveness: total site energy related to IT energy. Global average ≈ 1.54.
RackCabinet housing the IT equipment; the base unit of thermal sizing, expressed in kW.
RANSReynolds-averaged Navier-Stokes equations, the standard formulation of industrial studies.
RCIRack Cooling Index: indicator of the compliance of intake temperatures with the recommended ranges.
Rear-door heat exchangerHeat exchanger mounted on the rear door of a rack, capturing the heat as it leaves the servers.
RecirculationReturn of the rejected hot air towards the rack intakes, before cooling.
Richardson numberRatio of buoyancy forces to inertial forces; indicates which of the two drivers dominates the flow.
RTIReturn Temperature Index: ratio of the unit ΔT to the IT ΔT. Detects bypass and recirculation.
SHI / RHISupply / Return Heat Index: indicators of parasitic mixing between cold and hot air.
StratificationEstablishment of a stable vertical temperature gradient, with hot air accumulating in the upper part.
TenabilitySet of criteria (temperature, visibility, toxicity) defining bearable conditions for evacuation and intervention.
ThrottlingAutomatic reduction of a processor's frequency to limit its temperature. Loss of performance before failure.
Tier (I to IV)Uptime Institute classification of the topology and maintainability of an infrastructure.
TransientComputation following the evolution of quantities over time, indispensable for failures and fires.
Verification / validationVerify: are we solving the equations correctly. Validate: are we solving the right equations with the right data.
Who signs this white paper

A team document, not a single author

Who signs this white paper

At EOLIOS, a study is never the work of a single engineer: it is produced, recomputed and reviewed by a team. This white paper follows the same rule: it is signed by the Data Center team, and it is the consultancy that answers for it, not a person, exactly as for the studies we carry out.

EOLIOS Engineering
Data Center team · EOLIOS Engineering An independent computational fluid dynamics consultancy. We sell no equipment: our conclusions have no product to defend.
The consultancy Our published studies LinkedIn
350+data centers studied
15 yearsof CFD simulation
9offices in Europe and worldwide
HPCin-house computing resources + cloud

The content comes from our own assignments: on-site measurement campaigns, models tuned on survey data, failure scenarios computed in house. When a figure comes from an external reference, it is cited in appendix C; when it comes from our practice, it is written in the text.

01Writingby the engineers of the team who run the data center studies: airflow, thermals, fire, on-site measurement.
02Cross reviewby a second engineer of the team, who did not take part in the writing, as on our study reports.
03Validationby the team leader, then annual review to incorporate changes in density, standards and technologies.
Published by the Data Center team Reviewed internally, in double reading Updated on Next review July 2027
A question about your room? An engineer from the team will answer
Working with EOLIOS

Four weeks, from scoping to presentation

Our reference commitment on a data hall is four weeks, scoping and presentation included: and we know how to go faster when the works schedule demands it.

Week 1Scoping & surveyQuestions to settle, scope, measurement campaign and collection of operating data.
Week 2Model & calibrationGeometry, boundary conditions, comparison of the model with the measurements.
Week 3ScenariosNominal duty, degraded configurations, quantified remedy variants.
Week 4PresentationReport, RCI / RTI / Capture Index metrics, presentation meeting and action plan.
Discussing a specific room

A one-hour conversation is usually enough to say whether a CFD study is useful, and at what scope. We reply within 48 working hours.

eolios.eu/contactinfo@eolios.eu68 Leonard St, London EC2A 4QS, United Kingdom+33 1 42 25 45 21
Going further on eolios.eu

PUE calculation guide, data center digital twin, origin of overheating, external CFD of dry coolers, thermal study of technical rooms, and the detailed sheets of our assignments.

eolios.eu/data-center