Hyperscale Data Center – Mumbai, founded in 2008, is a leading data center and managed services provider in India. They operate 15+ data centers across the country, catering to industries such as BFSI, telecom, and IT/ITeS. The company offers a range of services, including hyperscale, colocation, work area recovery, and managed services. Hyperscale Data Center – Mumbai is known for its rapid growth and serves 20 of the Fortune 100 companies.

Mechartes was hired as a design consultant to carry out the structural and process design of the Thermal Energy Storage Tanks (TES) for the project. We designed the internals for TES and Buffer tanks, integrating advanced process design and structural analysis compliant with industry standards such as ASHRAE Applications Handbook-2007, AWWA D100, and ASME B31.1.

The thermal stratification observed inside the TES tank has a significant influence on the thermal performance of HVAC chiller systems. Our designs, validated through CFD analysis, have optimized energy efficiency and operational reliability during both charging and discharging cycles. The internals were designed to maintain reasonable thermal stratification inside the tank, confirmed by running CFD simulations.

Additionally, we designed the tank for wind and seismic conditions, including the nozzle design and the anchor chair. The seismic loads and supporting arrangements for the internals were calculated to ensure comprehensive design and structural integrity.

Mechartes was also responsible for conducting CFD analysis for the data halls to study the performance of the designed air conditioning system. Using CFD analysis, we ensured proper air circulation and verified that the designed temperatures at the service rack inlets were maintained. Additionally, we inspected the temperature in the hot aisle to ensure it was within acceptable limits and that no hot spots were present in the data hall.

The design was tested for various scenarios, including normal operation and transient simulations, such as cooling unit failures, power failures, and switching between main power and generator power. The final design, featuring the optimized floor tile configuration, was proposed to ensure that the temperature at the server rack inlets remained within the specified design range.