Controlling Gaseous and Particulate Contamination in Data Centers

Henri Yu1, and Chris Muller2,*

Purafil Asia, Guangzhou, China Purafil, Inc., Doraville, Georgia, USA * Corresponding Author. Tel: +1-770-662-8545, Fax: +1-770-263-6922, E-mail: cmuller@purafil.com
2 1

ABSTRACT Data centers operating in areas with high ambient pollution are experiencing corrosion-related hardware failures due to changes in electronic equipment brought about by recent lead-free regulations. Data centers located in areas with lower pollution levels may also experience similar problems especially when using air-side economizers for free cooling. When monitoring indicates that air quality does not fall within specified corrosion limits, enhanced air cleaning is required. Combination gas-phase / particulate air filters may be used to remove outdoor contaminants as well as any internally-generated contaminants to maintain acceptable air quality within the data center. This paper will discuss basic design requirements for the optimum control of contamination in data centers and the application of enhanced air cleaning. General aspects of air cleaning technology will be presented and where it may be used within the data center. Passive and real-time corrosion monitoring techniques used in data centers will be described. Air monitoring data will show that corrosive environments exist in locations that would otherwise be considered benign if not for the changes mandated by lead-free legislation. A case study will be presented showing the effectiveness of data center design modifications made in conjunction with the application of enhanced air cleaning. Keywords: Data center, Contamination control, Corrosion, Air cleaning, Air monitoring INTRODUCTION The European Union (EU) directive 2002/95/EC on the Restriction of the use of certain Hazardous Substances in electrical and electronic equipment or RoHS was implemented in July 2006 (EU 2003), and was the first of many RoHS (-like) regulations that have been passed. One aim being shared by almost all RoHS legislation is the elimination of lead in electronic products and these policies are generically referred to as Lead-Free legislation. Research has shown that printed circuit boards made using lead-free materials can be more susceptible to corrosion than their tin/lead counterparts (Mazurkiewicz 2006, Schueller 2007, Anon 2012, Anon A 20128, Anon B 2012) and it has been reported that many lead-free products will creep corrode in high sulfur environments. Creep corrosion failures have been reported on hard disk drives, graphic cards, and motherboards in many types of systems. Corrosion-induced failures are frequent in electronics products used in industrial environments. Now electronics in environments previously considered benign with regards to corrosion are experiencing serious problems as a direct result of RoHS. Data centers in many urban locations have reported failures of servers and hard disk drives due to sulfur corrosion (Crosley, et al. 2009). Desktop and laptop computers, servers, data communications (datacom) equipment and other information technology (IT) equipment are now at risk due to RoHS.

This is even being seen in personal computers and electronic devices. Performance degradation can occur rapidly or over many years, depending on specific conditions at a site. There are three types of gases that can be considered as prime candidates in the corrosion of data center electronics: acidic gases such as hydrogen sulfide, sulfur and nitrogen oxides, chlorine, and hydrogen fluoride; caustic gases, such as ammonia; and oxidizing gases, such as ozone. Of these, the acidic gases are of particular concern. Corrosive gases and submicron particulates in urban environments come from motor vehicle exhaust, emissions from other forms of transportation, heat and power generation, and industrial activity. In electronic component corrosion, sulfur oxides, active sulfur compounds, and inorganic chlorides are of primary interest. Although most data centers are protected against temperature and humidity variations, particulates and acidic gases can be drawn in through the building's air handling system(s) causing corrosion of electronics especially in equipment produced since the passage of RoHS regulations. Each site will have different types and concentrations of gaseous contaminants. DATA CENTER ENVIRONMENTAL ASSESSMENT A simple quantitative method to determine the airborne corrosivity in a data center environment is by reactivity monitoring as described in ANSI/ISA Standard 71.04-1985 Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants (ISA 1985). Copper coupons are exposed to the environment for a period of time and quantitatively analyzed to determine corrosion film thickness and chemistry. Silver coupons must also be used as part of an assessment to provide a complete accounting of the types of corrosive chemical species in the data center environment. ISA 71.04-1985 classifies four levels of environmental severity for electrical and electronic systems providing a measure of the corrosion potential of an environment (Table 1). G1 is benign and GX is open-ended and the most severe. Table 1. Classification of Reactive Environments
Class Severity Level Copper Reactivity* Comments G1 Mild <300 Corrosion is not a factor in determining equipment reliability. G2 Moderate <1000 Corrosion effects are measurable and corrosion may be a factor. G3 Harsh <2000 High probability that corrosive attack will occur. GX Severe 2000 Only specially designed and packaged equipment will survive.

ISA 71.04 bases the severity level on copper corrosion alone, and leading manufacturers of IT equipment have determined that the use of a modified ISA classification based on both copper and silver corrosion rates is more accurate for characterizing the environment towards newer RoHS-compliant electronic equipment. The best methods to classify the data center environment use corrosion classification coupons (CCCs) and/or real-time atmospheric corrosion monitors ([ACMs] England, et al. 1999, Muller 2010). The increasing number of hardware failures in locations high in sulfur-bearing gases, highlighted by the number of recent publications on the subject, led to the publication of a white paper on particulate and gaseous contamination (ASHRAE 2011) recommending that gaseous contamination should be within the modified severity level G1 which meets:

Corrosion is reported as angstroms () normalized to a 30-day exposure.

A copper reactivity rate of less than 300 /month and A silver reactivity rate of less than 200 /month.

The word modified is used because Standard 71.04 uses copper reactivity alone to determine severity levels and it is felt by many that copper alone cannot provide as complete a picture of the corrosion risk as when using copper and silver. The use of new PCB surface finishes for RoHS compliance especially those using silver and/or silver alloys as a replacement for lead and this new susceptibility of electronic equipment to environments previously considered benign has fostered an increased interest in environmental monitoring and classifications in both industrial and non-industrial settings. Corrosion Monitoring CCCs should be placed throughout the data center to determine compliance with air quality specifications. ACMs are used in the controlled environment and on or in server cabinets to provide real-time data on corrosion rates and the effectiveness of corrosion control strategies. Proper assessment will require monitoring of the outdoor (ambient) air and at various locations inside and outside the data center. ASHRAE specifically recommends monitoring of the computer racks at one-quarter and three-quarter height off the floor (ASHRAE 2009). Table 2 shows CCC monitoring results from different data centers in China. All locations had experienced corrosion-related equipment failures. What should be noted is that those locations exhibiting a G1 severity level according to ISA Standard 71.04, the corresponding silver corrosion rates are least one severity level higher and more often 2-3 levels higher. Table 2. CCC Data for Data Centers in China [Purafil 2009]
Silver Corrosion ISA Modified Location Cu2S Cu2O Cu-Unk Total Class AgCl Ag2S Ag-Unk Total ISA Class Bank HQ Tianjin 0 69 0 69 G1 0 623 0 623 G2 Bank Beijing 0 75 0 75 G1 0 636 0 636 G2 Financial Services Beijing 110 40 0 150 G1 0 1,680 0 1,680 G3 Electronics Co. HQ Shanghai 92 88 0 180 G1 0 2,421 0 2,421 GX Financial Services Shanghai 70 121 0 191 G1 0 1,253 145 1,398 G3 Bank Shanghai 0 205 0 205 G1 0 1,309 0 1,309 G3 Financial Institution HK 143 69 0 212 G1 0 1,434 0 1,434 G3 Banking Co. Shanghai 139 90 0 229 G1 0 491 0 491 G2 Bank Shenzhen 159 91 0 250 G1 0 909 0 909 G2 Investment Co. Beijing 0 268 0 268 G1 835 96 96 1,027 G3 Financial Services Beijing 248 67 0 315 G2 0 1,666 0 1,666 G3 Bank Shanghai 258 89 0 347 G2 0 1,047 0 1,047 G3 Banking Company HK 230 121 0 351 G2 0 1,476 0 1,476 G3 Bank Shenzhen 265 91 0 356 G2 0 3,200 0 3,200 GX Industrial Co. HQ Dong Ying 299 80 0 379 G2 0 1,603 0 1,603 G3 Bank Jinan 334 75 0 409 G2 0 1,833 0 1,833 G3 Electronics Co. HQ Zhuhai 0 465 0 465 G2 0 1,549 0 1,549 G3 Bank Beijing 426 85 0 511 G2 0 861 0 861 G2 Bank HQ Tianjin 415 179 0 594 G2 0 1,122 0 1,122 G3 Bank Shanghai 587 180 0 767 G2 45 1,742 0 1,787 G3 G1 copper coupon average: 183 Corresponding silver coupon: 1,193 G3 G2 copper coupon average: 449 Corresponding silver coupon: 1,614 G3 Copper Corrosion

The total corrosion measured is actually the sum of individual corrosion films: Cu 2S = copper sulfide, Cu2O = copper oxide, CuUnk = copper unknowns, AgCl = silver chloride, Ag2S = silver sulfide, AgUnk = silver unknowns. All data is normailzed to a 30-day exposure.

A common factor when using CCCs in data centers experiencing corrosion failures is that the silver corrosion averages 4-5 times higher. Because of this, silver is now considered a much better indicator of the corrosive potential of the data center environment and is becoming a warranty requirement for new datacom and IT equipment for several major manufacturers. CONTAMINATION CONTROL FOR DATA CENTERS Increasingly, enhanced air cleaning is being used in data centers to provide and maintain acceptable air quality. Using the proper type(s) of air cleaning technologies can reduce airborne contaminants to below specified levels and minimize equipment failure rates. There is no one standard for data center design, much less standards for contamination control for mission critical applications. However, several groups and organizations have either published or are currently working on environmental standards and/or guidelines. Gaseous & Particulate Contamination Guidelines for Data Centers (ASHRAE 2009). ASHRAE Technical Committee 9.9 Datacom Series (ASHRAE 2010). Planning and Design for Green Data Center (Zhong, et. al 2010). Usage Model Roadmap, Open Data Center Alliance (Anon C 2012). Corrosion Control for Mission Critical Facilities (Purafil 2011). BASIC DATA CENTER DESIGN REQUIREMENTS Before one considers adding enhanced air cleaning to control contamination in a data center, there are specific mechanical design requirements that must be understood and addressed. Temperature & Humidity Control The corrosive potential of any environment increases dramatically with increasing relative humidity. Rapid changes in relative humidity can result in localized areas of condensation and, ultimately, in corrosive failure. ASHRAE TC 9.9 published the ASHRAE Environmental Guidelines for Datacom Equipment (ASHRAE 2011) which extended the temperature-humidity envelope to provide greater flexibility in data center facility operations, with the goal of reducing energy consumption. All major IT manufacturers have agreed to these guidelines and today for high reliability, data centers should be operated in the recommended temperature range of 18C (64.4 F) - 27C (80.6 F). A downside of expanding the temperature-humidity envelope is the reliability risk from higher levels of gaseous and particulate contamination entering the data center where free cooling is being used. Room Air Pressurization To prevent infiltration of contaminated air, all critical areas must be maintained at a positive pressure relative to the space outside these areas. Proper Sealing of Protected Space Without a tightly sealed room, it will be very difficult to provide and maintain pressurization. This should include sealing any space above a drop ceiling or below a raised floor.

Room Air Recirculation If the data center envelope is well-sealed, there is low pedestrian traffic, and levels of internally-generated contamination are low, pressurization alone may be sufficient to provide an acceptable level of contamination control. The rate of room air recirculation will be determined by the type of mechanical equipment used and the construction parameters of the data center. ADVANCED DATA CENTER DESIGN REQUIREMENTS Air cleaning may involve several technologies depending on whether outdoor air is used for ventilation, pressurization, and/or (free-) cooling, or whether CRAC units are used as 100% recirculating air systems. Effective control of contaminants requires an optimized air cleaning strategy employing separate filters for particulate and gaseous contaminant control. If this is not practical, air cleaning may be integrated directly into the makeup (fresh) air systems, CRAC units or applied as stand-alone systems. Most air handling systems have particulate filtration and it should be determined what limitations there might be for the addition of gas-phase air filters. Particulate Filtration The control of particulates can be achieved through a number of common technologies. Recommended particulate filtration requirements for data centers have been published (ASHRAE 2009). It is important that all air handlers serving the data center have the appropriate particulate filters to ensure specified conditions are maintained. Gas-Phase Air Filtration There are also many options available for the control of gaseous pollutants. This type of air cleaning is less well understood and not as easily applied because most air handling systems and CRAC units may not be designed to accommodate this type of air cleaning technology. Gas-phase air filters used in combination with particulate filters are very effective in controlling most common pollutants and allows for complete pollutant control within the same system. Granular adsorbents in either bulk-fill or modular systems are commonly used. Now, however, due to advances in filtration technology new gas-phase filtration products including adsorbent-loaded nonwoven fiber media (ALNF, Middlebrooks and Muller 2001) and monolithic extruded carbon composites (ECC, Muller and Jin 2009) are now available. Gaseous air cleaning can be used in conjunction with the existing air handling systems and can be applied in several locations inside and outside the data center. With proper design considerations, filters can be added to existing air handling equipment or supplied as standalone pressurization and/or recirculation equipment. Examples of these include: Makeup (outdoor) air handlers (MAU) Air-side economizers Recirculating air handlers (RAH) Positive pressurization units (PPU) Computer room air conditioners (CRAC) Under-floor air filtration

DATA CENTER CONTAMINATION CONTROL CASE STUDY A data center had experienced hardware failures due to corrosion and the owners wanted to improve to prevent future failures. Previous CCC monitoring had indicated elevated levels of sulfur contamination in the outdoor ventilation air and in the data center itself. The ISA

severity level was a high G2 and the owners wanted reduce this to meet their internal specification of <100 / 30 days for both copper and silver. Recommendations were made for improvements to the data center envelope which included sealing and pressurizing the room and for the addition of enhanced air cleaning systems. One gas-phase air filtration system was installed to provide clean ventilation (outdoor) air for pressurization and four recirculation systems were installed inside the data center to provide additional air cleaning along with improved air distribution of the clean air. These systems were started up in January 2010. There was a dramatic and immediate decrease in the silver corrosion rates indicating the sulfur contamination was being removed. Further improvements made in April resulted in even lower corrosion rates. A management decision was made to turn off the outdoor air filtration system in early June to determine if this additional air cleaning was required to maintain the specified corrosion levels in the data center. As a result, immediate and significant increases were observed in both the copper and silver corrosion rates which led to the system being turned back on in July. Corrosion rates began to decline but it was determined soon afterwards that the gas-phase air filtration media in each of the systems was nearly spent and all filters were replaced. At the same time chemical filters were added to the CRAC units and corrosion rates again decreased. The Senior IT Specialist overseeing operation of the HVAC and air cleaning systems at this location reports that: It is a fact that the hardware failure rate has decreased after implementing the air filtration project in the computer room. My company produces and uses the latest computer technologies and we rely on the gas-phase air filtration in the data center to assure that the systems working in a safe environment. The air quality is much better now than before. (See Table 4). Table 4. Corrosion Monitoring Summary for Chinese Data Center
Date Copper Silver 2009 Dec 39 622 Jan 61 401 Feb 29 166 Mar 41 163 Apr 41 129 May 41 147 2010 Jun Jul 110 158 464 523 Aug 179 349 Sep 123 338 Oct 84 121 Nov 159 151 Dec 56 139 2011 Jan Feb 50 74 135 273

SUMMARY

Electronic equipment used in data centers are protected against the potential threats posed by fire, power, shock, humidity, temperature and (to a degree) particulate contamination. Unfortunately, the potential damage to this equipment caused by the corrosive effects of gaseous contaminants has still not been fully addressed. Recognizing the severity of the problem, the world's leading manufacturers of computer systems developed particulate and gaseous contamination guidelines for data centers (ASHRAE 2011) that summarize the acceptable levels of contamination as shown in Table 5. Enhanced air filtration systems for data centers should be designed to ASHRAE guidelines. The length of time that these levels of cleanliness can be provided is a function of the total contaminant load, air cleaning system design and filters/equipment employed. Major factors that may cause the data center environment to exceed these classifications are room sealing and pressurization. In properly sealing a room, often the spaces beneath raised floors and/or the space above dropped ceilings are neglected. These areas are critical, especially when they are used as supply and return plenums.

Table 5. Particulate and Gaseous Contamination Guidelines for Data Centers

Data centers must be kept clean to ISO 14644-1 Class 8. This level of cleanliness can generally be achieved by an appropriate filtration scheme as outlined here: 1. The room air may be continuously filtered with MERV 8 filters as recommended by ASHRAE Standard 127-2007, Method of Testing for Rating Computer and Data Processing Room Unitary Air Conditioners (ASHRAE 2007). 2. Air entering a data center may be filtered with MERV 11 or MERV 13 filters as recommended by the ASHRAE handbook titled Particulate and Gaseous Contamination in Datacom Environments (ASHRAE 2009b). Sources of dust inside data centers should be reduced. Every effort should be made to filter out dust that has deliquescent relative humidity greater than the maximum allowable relative humidity in the data center. Gaseous contamination should be within the modified ISA-71.04-1985 severity level G1-Mild that meets: 1. A copper reactivity rate of less than 300 angstroms () per month, and 2. A silver reactivity rate of less than 200 per month. For data centers with higher gaseous contamination levels, gas-phase filtration of the inlet air and the air in the data center is highly recommended.

With the increasing pressure to reduce energy consumption in data centers, and the increasing use of air-side economizers, data centers located in regions with poor ambient air quality will struggle to maintain efficient operations without the application of enhanced air cleaning. This means adding gas-phase air filtration and increasing particulate filter efficiencies. The issue and potential problem of corrosion in data centers has already been presented (ASHRAE 2009b, Muller 2010, Singh 2010). The problem needs to be addressed by monitoring the environment and removal of contaminants where indicated. Ultimately, the successful implementation of a contamination control program requires: Knowledge and understanding that corrosion of electronic equipment is a serious problem. Commitment to a monitoring program to determine the potential for equipment failure. Commitment to an integrated contamination control system. Commitment to take corrective action whenever necessary. REFERENCES Anonymity http://www.smta.org/knowledge/proceedings_abstract.cfm?PROC_ID=1765, last accessed March 1, 2012. Anonymity A http://www.emtworldwide.com/article.aspx?ArticleID=13556, last accessed March 5, 2012. Anonymity B http://www.era.co.uk/news/rfa_feature_03.asp, last accessed March 5, 2012. Anonymity C http://www.opendatacenteralliance.org/roadmap, last accessed March 5, 2012. ASHRAE. 2007. ANSI/ASHRAE Standard 127-2007, Method of Testing for Rating Computer and Data Processing Room Unitary Air Conditioners. Atlanta: American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc. ASHRAE. 2009. Particulate and Gaseous Contamination in Datacom Environments, Atlanta: American Society of Heating, Refrigeration and Air-Conditioning Engineers, Inc. ASHRAE. 2011. 2011 Gaseous and Particulate Contamination Guidelines for Data Centers. Atlanta: American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc. ASHRAE. 2011. 2011 Thermal Guidelines for Data Processing Environments Expanded Data Center Classes and Usage Guidance. Atlanta: American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc.

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