GB2579164A - Fire Barrier - Google Patents

Abstract

The building comprises a floor and ceiling. The fire barrier comprises panels 1011 supported by a frame 1010 The method comprises attaching the fire barrier frame to a side of a module 1001 . Transporting the module with the attached barrier. Positioning the module between the floor and ceiling of a building and attaching the fire barrier frame to at least either the floor or ceiling. Also claimed is a module with the fitted fire barrier which defines an interior space. Also claimed is a services module for a data centre comprising a frame for holding fire barrier panel and a services module for installation to a data centre including hot and cold aisles. The fire barrier may include a fire damper attached to the fire barrier frame.

Description

-I -

Fire Barrier

Field of the Invention

The present invention concerns a method of constructing a fire bather in a building, a building module comprising such a fire barrier, and a building comprising a fire barrier constructed according to the method and/or comprising the building module. In particular, the building may be a data centre and the module may be a services module for a data centre.

Background of the Invention

A data centre is a late 20th Century development that has grown as a response to the increasing demand for computer processing capability and a recognition of the importance of IT in the place of every business and organisation today. With the ever-increasing demand for computing capacity in recent years, many large organisations have invested in data centres comprising many networked computer servers known as blades installed in racks enabling controlled and modular expansion of capacity. Data centre facilities can require a floor space ranging from a few hundred square feet to a million square feet. The most prevalent size for a small data centre is five to ten thousand square feet with fifty to a hundred thousand square feet being the most common floor area requirement for a large data centre.

For many industries, the modern data centre is a mission-critical facility, failure of which (even if only for a short time) could result in serious or even irreparable harm to the organisation. For that reason, modern data centres are designed to be resilient, and typically include dedicated mechanical and electrical (M&E) plant to deliver power, cooling and fire suppression with built-in redundancy with the aim of providing near continuous operation. In particular, modern data centres typically include redundant or backup power supplies, including for example on-site generators. It will be appreciated that computer servers are typically unable to tolerate even a momentary loss in power, and so modern data centres typically include some form of uninterruptible power supply (UPS) system to bridge the gap between the main power source (e.g. the national grid) going offline and the backup power source (e.g. on-site generators) reaching full operational capacity. Various different -2 -UPS systems are used in data centres around the world, including battery systems and flywheel systems. A common feature of most UPS systems is the use of a UPS switchboard for controlling the UPS system.

In a modern, large-scale data centre, it is not just the power supply to the IT equipment that is critical to continuous operation of the data centre. The high density of IT equipment often present in a modern data centre typically means that the IT equipment requires continuous active cooling. If the cooling system should fail, it is often the case that the IT equipment rapidly overheats, which can lead to damage or even failure of the equipment. Accordingly, the cooling systems of modern data centres are often also connected to UPS equipment. It will be appreciated that the power demands of the cooling system are not necessarily the same as the power demands of the IT equipment, and so in some data centres, the air cooing system is provided with its own, dedicated, main and backup power supply switchboards and UPS systems.

In order to provide a resilient data centre facility, critical components of the data centre are often duplicated to provide redundancy. Various standards exist for categorising the resilience level of modern data centres. One measure of data centre resilience is defined by the Uptime Institute's 'Tier Standard' which sets out the minimum requirements for a data centre to be given a Tier Level of between I and IV.

Duplication of critical components can help to avoid failure of the entire data centre in the event of failure of one critical component. For this reason, IT equipment and other essential data centre components (such as the air cooling system) are often provided with a dual power supply.

It follows from the above that a modern data centre facility may include a large amount of electrical control equipment.

Often, to make efficient use of space and to simplify installation and maintenance, UPS equipment is concentrated in one or more designated areas of the data centre. One such approach is to provide a dedicated services area/services room for housing UPS equipment. Often, other service equipment, such as main power supply switchboards and backup power supply switchboards (including, e.g., generator control equipment) are co-located in such a dedicated services areas. It will be appreciated that since the power supply switchboards, the UPS switchboards and the backup power supply switchboards are usually connected to the same electrical -3 -circuits (i.e. the circuits supplying power to the IT equipment in the data centre), it is often convenient to house them in the same area of the data centre.

Fire safety is another important aspect of building design, and national building regulations typically set out strict requirements for fire safety. For example as set out in the UK in 'Approved Document B -Volume 2 -Buildings Other Than Dwelling Houses' of 'The Building Regulations 2010'. In one aspect, fire safety regulations indicate to what extent and for how long 1) a building's structural integrity should be maintained in the event of a fire, and 2) spread of fire through a building should be prevented. It is often the case that in large buildings (such as data centres) some degree of compartmentalisation is incorporated in the structure of the building in order to inhibit or at least slow down the spread of a conflagration. Where a building is separated into compartments, 'Approved Document B' states that every compartment wall and compartment floor should form a complete barrier to fire between the compai tments they separate. That document further indicates the minimum fire resistance that should be provided by a compartment wall or compartment floor. Typically, fire resistance is defined in terms of the time (in minutes) that a barrier is able to prevent fire penetration and/or transfer of excessive heat. In the UK, fire rating tests are specified in British Standard B 5:476, with specifications for walls in buildings contained in British Standard BS:476-22.

When building compartmentalisation having a fire barrier entirely separating one area of the building from another is used, it is often necessary to allow people and/or air to move around the building during normal operation (i.e. when there is no fire). Accordingly, such fire barriers are often provided with openings that can be closed by fire doors and/or fire dampers in the event that a fire is detected. In those cases, such fire doors/dampers are an integral part of a fire barrier, and should provide a fire resistance appropriate to ensure that the overall fire barrier provides its designed fire resistance. In some circumstances, a wall within a building may be constructed entirely from a fire barrier material. Additionally or alternatively, the fire resistance of an internal wall may be upgraded by providing it with a lining of material having a higher fire resistance.

One approach to deciding how to compartmentalise a building is to review the fire risk posed by each area of a building. Often, when particular types of equipment are concentrated into one area of a building, that area lends itself to compartmentalisation. It will be appreciated that the high density of electrical -4 -switchgear in the services area of a data centre presents a particular fire risk. Accordingly, it is often desirable to provide a fire barrier between the services area of a data centre and one or more other internal areas of the data centre, such as the IT area (i.e. an area housing multiple sewer racks) and/or the cooling equipment area.

An especially active area in data centre design has been in the development of modular data centre systems, where the data centre is componentised and constructed from kits of parts. In some designs, the data centre is constructed from a plurality of volumetric' modules (e.g. structural sections of the data centre that are transported to the data centre site from a remote manufacturing facility and then connected together on-site to form the data centre). A disadvantage with such an approach is that it can result in transporting large boxes containing substantial amounts of free space. Other modular construction methods utilise flat-packed kits of parts that can be transported efficiently and also assembled rapidly on site. It is often the case that the data centre building/structure is sourced separately to the IT equipment, not least because such an approach allows the data centre operator to provide itself with plenty of capacity without committing to the purchase of large quantities of expensive IT equipment. That approach is especially popular in co-location data centre projects where the data centre operator may only provide space for customers to install their own IT equipment. Such flat-pack approaches may not, however, be the most desirable solution for all parts of the data centre.

Installation of a regulation-compliant a fire barrier often requires a significant degree of care and expertise. Typically, data centre fire barriers are installed on-site by a specialist contractor. On-site installation and compliance verification can significantly impact the build time for a data centre There remains a need for improved designs of data centre services areas to improve construction and operational efficiency. Furthermore, there remains a need for such improved designs that can be utilised in modem, Tier II, Tier Ill and/or Tier IV compliant data centres.

Summary of the Invention

According to a first aspect, the present invention provides a method of constructing a fire barrier in a building, the fire barrier comprising a plurality of panels supported by a frame, the building comprising a floor and a ceiling, wherein the method comprises: a) attaching the fire barrier frame to an outer surface of a first side of a building module, the building module comprising a top, a bottom and a -5 -plurality of sides that together define an interior space; b) transporting the module and the attached fire barrier frame to the building; c) positioning the module and the attached fire barrier frame between the floor and the ceiling of the building; d) attaching the fire barrier frame to at least one of (i) the floor and (ii) the ceiling of the building. Preferably, the method comprises attaching the plurality of panels to the frame, for example subsequent to the step of attaching the frame to the building module. Optionally, the plurality of panels are attached to the fire barrier frame before the step of attaching the frame to the floor and/or ceiling of the building. Optionally, the plurality of panels are attached to the frame before the step of transporting the module to the building.

Optionally, the method comprises a further step of e) detaching the fire barrier frame from the first side of the building module. Preferably the step of detaching the fire barrier frame from the first side of the module is carried out after the step of attaching the frame to at least one of (i) the floor and (ii) the ceiling of the building.

Optionally, the plurality of panels are attached to the frame before the step of detaching the frame from the first side of the building module. It may be that the step of detaching the fire barrier frame from the first side of the module comprises detaching the frame from the top of the first side of the module. Optionally, the frame remains attached to the bottom of the first side of the module, for example it may be that the method comprises a step of attaching the bottom of the module to the floor of the building, thereby securing the frame to the floor of the building via the bottom of the module.

It will be understood that, typically, the outer surface of the first side of the module is opposed to an inner side, wherein the inner side faces the interior space of the module. It will be appreciated that the step of attaching the fire barrier to the building module is typically carried out at a location remote to the building, for example in a factory. It may be that such a method allows the fire barrier to be constructed in a controlled environment and in parallel to building work taking place on site. Accordingly, it may be that the method improves cost and time efficiency of construction.

Preferably, the building module is sized and configured for transportation by road, rail or water. For example, it may be that the external dimensions of the module are sized to allow transport of the module as a single unit in accordance with local (e.g. UK, European or US) public highway loading restrictions. Optionally, the -6 -module is a structural module suitable for forming an integral part of the building structure. For example, it may be that the module is suitable for forming a load-bearing part of the structure that supports one or more other parts of the building. Additionally or alternatively, the module is a free-standing module suitable for housing within a data centre building. For example, it may be that the module is suitable for positioning on a floor in a building. It will be understood that the module should be sufficiently robust to permit its transport. Preferably, the module with the fire barrier attached has an overall length of no more than 20 metres, such as no more than 15 metres, optionally an overall length of from 5 to 20 metres, such as 10 to 15 metres. Preferably, the module with the fire barrier attached has an overall width of no more than 5 metres, such as no more than 4 metres, optionally an overall width of 2 to 5 metres, such as 3 to 4 metres. Optionally, the module with the fire barrier attached has an overall height of no more than 5 metres, such as no more than 4 metres, optionally an overall height of 2 to 5 metres, such as 3 to 4 metres.

It will be appreciated that for a fire bather to provide adequate compartmentation within a building, it is often necessary to carefully control the size and shape of the fire barrier structure, e.g. to ensure a tight fit between the fire barrier and any adjoining walls/floors/ceilings. Furthermore, it is often the case that panels used to construct fire bathers are made from a relatively brittle material and are prone to damage. It will also be appreciated that the fire bather frame must typically remain true to its design shape and dimensions and that it is usually the case that only a low tolerance for deviation is acceptable. Yet further, in order for a fire barrier to pass an integrity fire test, it must not be solely supported by a structure that is not 'fireproof. In practice, this often means that a fire barrier should be free-standing or supported by other integrity fire-rated structures (such as the floor, external walls and roof/mezzanine floor of the building). For these reasons, even when the size and shape of the fire barrier is set during off-site design (and, in the case of modular buildings, during module construction), fire barriers are traditionally constructed on-site. Such on-site construction tends to be time consuming and inefficient in comparison to the rest of a modular build program. The present inventors have now found that such difficulties can be avoided by attaching a fire barrier to the side of a module that will be used to form part of a building. Thus, the fire barrier can be precisely manufactured off-site to suit the dimensions of its intended installation location, transported to site in a single consignment together with the module and with reduced -7 -risk of damage/distortion of its shape, and then affixed to fire-rated components of the building on-site. It will be appreciated that with such a construction, the first side of the module need not itself have an integrity fire-rated construction. It will be appreciated that if the fire barrier is subsequently detached from the side of the module, the fire barrier may be entirely independent of the module and thus benefit from an even greater degree of independent structural integrity.

It may be that one or more of the top, bottom and sides of the module are open. Optionally, the module comprises a frame, such as a frame defining at least one of, such as all of the top, bottom and sides of the module. In other words, it may be that at least some of the bottom, top and sides, preferably the top and sides, of the module are formed by an open framework. For example, it may be that the frame includes structural members extending along the vertices of the module. Optionally, the frame is fabricated from steel. Optionally, the bottom of the module is at least partially (e.g. fully) closed, for example forming a floor, such as a floor suitable for supporting people and/or equipment. Optionally, when the bottom of the module is at least partially closed, the bottom comprises a plurality of floor panels supported by a frame. Optionally, one or more sides of the module is at least partially closed, for example forming a wall. Optionally, when a side is at least partially closed, the side comprises a plurality of wall panels supported by a frame. It will be appreciated that an at least partially closed side of the module may include one or more openings, such as personnel access openings, service pass through openings and/or airflow openings. Optionally, the personnel opening comprises a door assembly comprising a door frame and a door. Optionally, the service pass through opening comprises a gasket or brush for closing the opening around the service once installed. Optionally, the airflow opening comprises an airflow damper, such as a fire damper. Optionally, the top of the module is closed, for example forming a ceiling. Optionally, when the top of the module is closed, the top comprises a plurality of ceiling panels supported by a frame.

Optionally, the method comprises attaching the fire barrier frame to an outer surface of a second side of the building module.

Optionally, the building is a data centre. Optionally, the module is a services module for a data centre, such as a services module for providing electrical power to electrical equipment in the data centre. For example, the module may be for -8 -distributing electrical power to IT equipment (e.g. computer servers) and/or mechanical equipment (e.g. one or more air handling units) in the data centre.

It will be appreciated that the ceiling of the building may be, for example, a roof and/or a mezzanine floor. It will also be appreciated that the floor of the building may be, for example, the bottom, mid or top floor of the building (e.g. being a floor slab on the bottom floor or a mezzanine floor on an upper floor). Preferably, the floor and/or ceiling of the building are fire-rated structures in the building. For example, it may be that the fire barrier together with the floor and/or ceiling of the building together define a continuous fire barrier. Optionally, the building comprises at least one wall, preferably wherein the method comprises attaching the frame of the fire barrier to the at least one wall once the module is positioned in the building. Optionally, the step of positioning the module comprises positioning the module adjacent the at least one wall. Optionally, the step of positioning the module comprises positioning the module adjacent, above or below a further building module having a fire barrier frame attached thereto. Preferably, such a method additionally comprises attaching the frame of the fire barrier of the module to the frame of the fire barrier of the further building module, for example such that the fire barrier of the module and the fire barrier of the further module form a continuous fire barrier.

Optionally, the interior space of the building module comprises a personnel area. It will be appreciated that a personnel area is a space sized and configured to allow a person to enter the space. Preferably, the personnel area has a height of at least 2 metres, such as at least 3 metres, optionally the personnel area has a height of from 2 metres to 5 metres, such as from 3 metres to 4 metres. Preferably the personnel area has a length and/or width of at least 0.5 metres, such as at least 1 metre, optionally the personnel area has a length and/or width of from 0.5 to 20 metres, such as 3 to 15 metres. Optionally, the interior space comprises at least one electrical equipment storage area, such as one or more electrical switchboard storage areas and/or one or more UPS switchboard storage areas. Optionally, the module defines a unitary space comprising a personnel area and an electrical equipment storage area. It may be that, once the module is installed and fitted with electrical equipment, one or more sides of the personnel area is defined by said electrical equipment. Optionally, the personnel area extends across at least 10 % of the internal width of the module, for example across at least 20 % of the overall width of the module, such as across at least 30 % of the overall width of the module. Optionally, -9 -the personnel area extends along at least 50 % of the overall length of the module, for example along at least 75 % of the length of the module, such as along substantially the whole (e.g. the whole) length of the module. Preferably, the personnel area provides personnel access to the electronic equipment storage area(s), for example providing personnel access to equipment accommodated in the electronic equipment storage area(s) when the module is installed and fitted with said equipment.

An electrical equipment storage area is a space within the module sized and configured to configured to accommodate electrical equipment, such as one or more electrical switchboards and/or one or more UPS switchboards. Optionally, the at least one electrical equipment storage area extends across at least 20 % of the internal width of the module, for example across at least 30 % of the overall width of the module, such as across at least 50 % of the overall width of the module. Optionally, the at least one electrical equipment storage area extends along at least 50 sio of the overall length of the module, for example along at least 75 of the length of the module, such as along substantially the whole (e.g. the whole) length of the module.

Preferably, the module comprises at least two electrical equipment storage areas, such as two electrical equipment storages areas positioned on opposing sides of the personnel area.

Preferably, the at least one electrical equipment storage area of the module accommodates at least one UPS switchboard and/or at least one electrical switchboard, such as a plurality of UPS switchboards and/or a plurality of electrical switchboards. It may be that including said switchboards in the module allows the module to be constructed and commissioned off-site, thus providing a 'plug and play' module that can be conveniently transported to site and rapidly installed.

Preferably, the method comprises attaching the plurality of panels to the frame of the fire barrier after the step of attaching the frame to the building module. Optionally, the method comprises sealing the plurality of panels together to form a continuous fire barrier, for example wherein the panels are sealed together using a fire rated sealant, such as a mastic sealant. Additionally or alternatively, it may be that the panels are provided with a gasket material that swells in response to heat to close any gap between the panels, and/or the panels comprise such a material at their peripheral edges. Optionally, each panel has a sandwich construction, e.g. comprising an inner insulation later sandwiched between outer stiffening layers. Optionally, each stiffening layer comprises an inner layer of plasterboard overlaid with an outer layer -10 -or vinyl coated steel. It will be appreciated that any suitable fire barrier panel can be used with the present invention. Optionally, each panel additionally comprises a panel frame, wherein the panel frame is attached to the frame of the fire barrier. Preferably, the fire barrier comprises a fire door assembly, such as a fire door assembly comprising a door frame and a door. Optionally, the fire barrier comprises a plurality of fire door assemblies, for example including a fire door assembly positioned on the first side of the building module, and a further fire door assembly positioned on the second side of the module. Optionally, the fire door assembly has a l-hour fire rating, such as a 1-hour integrity/insulation fire rating according to BS:476-22. Optionally, the method comprises attaching the fire door assembly to the frame of fire barrier, optionally wherein the fire door assembly is attached to the frame after the step of attaching the frame to the building module. Preferably, the fire door assembly is attached to the frame of the fire barrier before the step of attaching the frame to the building, and/or before the step of transporting the building module, optionally and/or before the step of detaching the frame from the building module.

Optionally, the fire barrier panels, fire barrier frame, and fire door assembly together provide a fire barrier, such as a fire barrier suitable for providing a 1-hour fire barrier, such as a 1-hour integrity/insulation fire barrier according to BS:476-22. It may be that the module is configured so that, in normal operation, the fire door is can be held open so that personnel access into and out of the module is permitted, and so that, in the event of a fire, the fire door closes, e.g. closing automatically in response to a signal received from a fire control system. For example, it may be that the fire door is movable between a first, open position in which personnel access to the module is permitted, and a second, closed position in which the fire door provides a fire barrier across the door assembly. Optionally, the door assembly additionally comprises a vented door for controlling personnel access into the module and for controlling airflow into the module during normal use. An example of a suitable vented door is disclosed in International (PCT) Publication No. W02010/139921 A 1, the contents of which are incorporated herein by reference. For example, it may be that the first side of the module comprises a personnel opening, wherein the personnel opening comprises a fire door and a door having an adjustable vent (i.e. a vented door). It will be appreciated that the vented door and the fire door of the door assembly may, optionally, be structurally independent. For example, it may be that the door assembly comprises a first vented door frame supporting the vented door, and a second door frame supporting the fire door. It may be that the module is configured so that, in normal operation, the fire door is held open so that personnel access through the opening is controlled by the vented door, and so that, in the event of a fire, the fire door closes, e.g. closing automatically in response to a signal received from a fire control system. For example, it may be that the fire door is movable between a first, open position in which personnel access to module is controlled by the door comprising the adjustable vent, and a second, closed position in which the fire door provides a fire bather across the door assembly.

Optionally, the fire barrier comprises at least one fire damper. Optionally, the fire barrier comprises a plurality of fire dampers, for example wherein a plurality of fire dampers are positioned on the first side of the building module. Optionally, the fire damper is comprised in an airflow opening in the first side of the module. Optionally, the fire damper has a 1-hour fire rating, such as a 1-hour integrity/insulation fire rating according to BS:476-22. Optionally, the method comprises attaching the fire damper to the frame of the fire barrier, optionally wherein the fire damper is attached to the frame after the step of attaching the frame to the building module. Preferably, the fire damper is attached to the frame of the fire barrier before the step of attaching the frame to the building, and/or before the step of transporting the building module, optionally and/or before the step of detaching the frame from the building module. Optionally, the fire barrier panels, the fire barrier frame, and the fire damper together provide a fire barrier, such as a fire barrier suitable for providing a 1-hour fire barrier, such as a 1-hour integrity/insulation fire barrier according to BS:476-22. Optionally, the fire damper comprises a plurality of rotatable fins housed within a frame defining an opening, wherein the fins are rotatable between an open position in which airflow through the opening is permitted and a closed position in which airflow through the opening is inhibited. It may be that the module is configured so that, in normal operation, the fire damper is held in an open position in which air is able to flow into or out of the module, and so that, in the event of a fire, the fire damper closes, e.g. closing automatically in response to a signal received from a fire control system. Preferably, the fire damper is configured for connection to a fire control system comprising a controller and a plurality of sensors. Preferably, the plurality of sensors includes one or more smoke, heat and/or flame sensors. Optionally, the module comprises at least one duct for channelling -12 -exhaust air from one or more UPS switchboards accommodated in the module to the fire damper.

Optionally, when the fire barrier comprises panels, a fire door assembly and a fire damper, the panels, frame, fire door assembly and fire damper together provide a fire barrier, such as a fire barrier suitable for providing a 1-hour fire barrier, such as a 1-hour integrity/insulation fire barrier according to BS:476-22.

Optionally, the frame of the fire barrier comprises at least one of a top rail and a bottom rail, such as a top rail for attaching the frame to the ceiling of the building and/or a bottom rail for attaching the frame to the floor of the building. Optionally, the frame of the fire barrier comprises at least one side rail, such as a side rail for attaching the frame to a wall of the building. Preferably, the or each rail comprises a plurality of fixing points, such as holes, for accommodating fixings for attaching the rail to the building. Optionally, the step of attaching the fire barrier to the building comprises fixing the or each rail to the building. Optionally, the rail is screwed or bolted to the building.

According to a second aspect, the present invention provides a building module fitted with a fire barrier, wherein the building module comprises a bottom, a top and a plurality of sides defining an interior space; wherein the barrier comprises a frame for supporting a plurality of panels, and wherein the frame of the fire barrier is attached to an outer surface of a first side of the building module. Preferably, the fire barrier comprises a plurality of panels supported by the frame. Optionally, the building module fitted with a fire barrier is suitable for use in the method of the first aspect of the invention. It will be appreciated that the building module and fire barrier of the second aspect of the invention may optionally include any feature described in relation to the method of the first aspect of the invention, and vice versa.

Optionally, the fire barrier is releasably attached to the outer surface of the first side of the building module.

According to a third aspect, the present invention provides a services module for a data centre, the services module comprising a floor and a plurality of sides defining an interior space, wherein a first side comprises (i) a primary frame having opposed inner and outer surfaces, the inner surface facing the interior space of the module, and (ii) a secondary frame attached to the outer surface of the primary frame, wherein the secondary frame is suitable for supporting a plurality of fire barrier panels. Optionally, the first side comprises a plurality of fire barrier panels attached to the secondary frame. Preferably, the secondary frame and the fire barrier panels together provide a fire barrier suitable for providing a 1-hour fire barrier, such as a 1-hour integrity/insulation fire barrier according to BS:476-22.

Optionally the secondary frame is detachable from the primary frame, e.g. detachable from the top of the primary frame.

Optionally, the services module is a transportable module, for example a module that is sized and configured for transportation by road, rail or water.

Optionally, the secondary frame is releasably attached to the primary frame, e.g. with a plurality of fixings, such as a plurality of bolts and/or screws, e.g. a plurality of self drilling screws. Optionally, the plurality of fixings are removable fixings that are removed in order to detach the secondary frame from the primary frame.

Preferably, the services module is configured for installation in a data centre for accommodating a plurality of racks of IT equipment, the data centre comprising (a) a plurality of hot aisles interleaved with a plurality of cold aisles, wherein each hot aisle is separated from an adjacent cold aisle by a rack storage area, each rack storage area being arranged to accommodate a row of racks of IT equipment, and (b) an air handling unit configured to supply cooling air to the rack storage areas via the cold aisles. The module is preferably configured to provide in the data centre at least part of a services area for accommodating at least one uninterruptible power supply (UPS) switchboard for directing electrical power to a plurality of racks of IT equipment. Preferably, the services area comprises at least one hot zone and at least one cold zone, the at least one hot zone being separated from the at least one cold zone by at least one of 0) a UPS switchboard storage area and (ii) a partition, the UPS switchboard storage area being configured to accommodate at least one UPS switchboard. Preferably, the module is configured so that, once installed in the data centre, the UPS switchboard storage area receives cooling air from the air handling unit via the cold zone of the services area. Optionally, the module defines the cold zone of the services area.

Optionally, the services module comprises at least one UPS switchboard and at least one electrical switchboard, the UPS switchboard and electrical switchboard being configured to distribute electrical power to at least one of 0) the racks of IT equipment, and (ii) the air handling unit of the data centre.

-14 -It will be appreciated that the services module and of the third aspect of the invention may optionally include any feature described in relation to the method of the first aspect of the invention, and vice versa.

According to a fourth aspect, the present invention provides a building comprising a fire barrier, wherein the fire barrier is constructed according to the method of the first aspect of the invention. Preferably, the building is a data centre.

It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the invention may incorporate any of the features described with reference to the apparatus of the invention and vice versa.

Description of the Drawings

Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which: Figure 1 shows a plan view of a data centre according to an embodiment of the invention; Figure 2 shows an enlarged plan view of the services module of the data centre of Figure 1; Figure 3 shows a cross-sectional view of the services area of the data centre of Figure 1; Figure 4 shows a perspective view of the frame of a building module according to another embodiment of the invention; Figure 5 shows a perspective view of the building module of Figure 4 with the frame of a fire barrier attached to the frame of the module; Figure 6 shows a perspective view of the building module of Figures 4 and 5 in which the fire barrier comprises a plurality of panels mounted on the frame of the fire barrier; Figure 7 shows a plan view of the building module and fire barrier of Figure 6; Figure 8 shows a cross-sectional view through the building module and fire barrier of Figures 6 and 7; Figure 9 shows an enlarged detail plan view of part of the door assembly of the building module and fire barrier of Figures 6 and 7; -15 -Figures 10 and 11 show enlarged detail cross-sectional views of the joints between the fire barrier and the frame of the building module of Figure 8.

Detailed Description

As used herein, the term 'in use' means during the normal use of the item so described. For example, a data centre is 'in use' when operating normally and within its design limits, for example when the items of IT equipment housed in the data centre are functioning, and the air handling unit is operating to provide adequate cooling air to the items of IT equipment.

A data centre is a facility for housing large numbers of densely packed computer servers. One approach classifying data centre size is by the total power consumption of the data centre (when the data centre is at full IT equipment capacity). Small to medium-sized data centres may, for example, have a power consumption of 125 KW to 1.5 MW, large-scale data centres may have an power consumption of 10 MW to 50 MW (or, in some cases, above 100 MW). The power consumption of such large-scale data centres is comparable to the power requirements of a town of 7,000 to 35,000 households in the UK. The data centre of the present invention may be at least a 500 KW, such as at least a 1 MW, for example at least a 10 MW data centre.

As used herein, an electrical switchboard is a device for directing electricity from one or more sources of supply to one or more regions of usage; it is not a UPS switchboard. It is an assembly of one or more panels, each of which contains one or more switches that allow electricity to be redirected. Typically, switchgear is a combination of electrical disconnect switches, fuses or circuit breakers used to control, protect and isolate electrical equipment. A low voltage electrical switchboard (LVSB) is an electrical switchboard that is operated to direct low voltage electricity, defined by the International Electrotechnical Commission (IEC) as voltage in the range 50 to 1000 V AC or 120 to 1500 V DC. In electrical power systems, low voltage most commonly refers to the mains voltages as used by domestic and light industrial and commercial consumers. British Standard BS 7671:2008 defines supply system low voltage as: 50 to 1000 VAC or 120 to 1500 V ripple-free DC between conductors; 50 to 600 VAC or 120 to 900 V ripple-free DC between conductors and Earth. As used herein, an IT equipment electrical switchboard is an electrical switchboard used to direct electricity to IT equipment (i.e. computer servers) in the -16 -data centre, and a mechanical equipment electrical switchboard is an electrical switchboard used to direct electricity to non-IT equipment (including, e.g., cooling systems) in the data centre. As used herein, "'A' Supply" is a primary electrical circuit connecting an electrical switchboard to items of electrical equipment (including IT and mechanical equipment), and "'B' Supply" is a backup electrical circuit connecting the same electrical switchboard to the same items of electrical equipment.

As used herein, Uninterruptible Power Supply (UPS) system refers to electrical apparatus that provides emergency power to a load when the input power source or mains power fails. Typically, a UPS system differs from an auxiliary or emergency power system or standby generator in that it will provide near-instantaneous protection from input power interruptions, by supplying energy stored, e.g. in batteries. Often, the runtime of UPS power sources is relatively short (only a few minutes) but sufficient to start a standby power source or properly shut down the protected equipment. A UPS system may comprise a UPS switchboard and a UPS power source. Preferably, the UPS system is a static UPS system, for example wherein the UPS power source includes or consists of batteries and/or supercapacitors, preferably batteries. A UPS Switchboard is the electrical switchboard used for directing electricity between the UPS power source, electrical equipment (e.g. IT equipment and/or mechanical equipment) in the data centre, the main external power source (e.g. an external electric distribution network), and optionally the backup power source (e.g. on-site generators). Preferably, the UPS switchboard also functions as a rectifier for converting electrical current between alternating current and direct current.

As used herein, a fire barrier is a fire-resistant construction used to prevent the spread of fire for a prescribed period of time. A fire barrier can be used to subdivide a building into separate fire areas, and is usually constructed in accordance with locally applicable building codes. A fire wall is a particular type of fire barrier, typically being a fire barrier that is structurally self-sufficient. A fire barrier may be continuous from an exterior wall to an exterior wall, or from a floor below to a floor or roof above, or from one fire barrier to another fire barrier. Fire barriers are often give a time rating, such as a 1 hour' rating, in terms of integrity and/or insulation. Integrity refers to the ability of the fire barrier to remain standing for the specified time. For example, a 1-hour integrity fire rating test may involve exposing one side of a free- -17 -standing sample of the barrier to flames for an hour, throughout which the barrier must prevent passage of flames from one side to the other. In some tests, the barrier is subsequently sprayed with water at the end of the 1-hour period to ensure that the integrity of the barrier is maintained under fire-fighting conditions. Additionally or alternatively, a 1-hour insulation fire rating test may involve exposing one side of a sample of the barrier to flames for an hour, throughout which the temperature on the other side of the barrier should not exceed a pre-defined set point. In the UK, fire ratings are often assessed using British Standard B S:476-22.

Fire dampers are fire protection products used in heating, ventilation, and air conditioning (HVAC) ducts to prevent the spread of fire through ductwork that passes through fire-barriers. Fire/smoke dampers are similar to fire dampers in fire resistance rating, and additionally prevent spread of smoke through ductwork. It will be appreciated that any fire damper described herein may additionally be a smoke damper. Fire dampers can be activated by integral thermal elements (e.g. which melt at pre-defined temperatures thereby allowing springs to close damper blades) and/or by a central fire control system (e.g. that sends a control signal to the damper to operate motorised damper blades). Such a fire control system may include detectors proximal to and/or remote from the damper, which can sense heat or smoke in the building.

As used herein, 'IT equipment' includes computer servers, especially rack-mountable servers. A typical server rack may be configured to accommodate 42 individual sewers stacked vertically, and may have a width of 600 mm and a depth of 1070 mm. Other rack sizes are also available, for example racks able to accommodate 45, 48, 52 or 58 individual servers, with some racks being 750 mm or 800 mm wide and 1100 mm or 1200 mm deep. Rack heights are typically referred to in terms of rack units' or 'U', with one U having a height of 44.5 mm and typically being able to accommodate a single server.

A rack storage area is a space in the data centre provided for accommodating a plurality of racks, typically arranged in a row. Optionally, a single rack storage area may be configured to accommodate a row of at least 5 racks, such as at least 10 racks, for example at least 15 racks. Typically, each cold aisle is flanked on opposing sides by one or more rack storage areas. It will be appreciated that a single cold aisle may, for example, include two or more rack storage areas on each side with each rack storage area on each side being separated by a barrier such as a blanking panel. While -18 -a cold aisle may, in principle, be any length, it may be that a cold aisle has no more than 40, such as no more than 30, for example no more than 20 racks along its length on one (or each) side. It will be appreciated that, in use, each cold aisle may have 10 to 80, such as 20 to 60, for example 30 to 40 racks along its length. It will further be appreciated that the data centre may configured to accommodate IT equipment comprising at least 840, such as at least 1680, for example at least 2520 individual servers.

A data centre 1 according to an embodiment of the invention is shown in Figure 1. The data centre 1 uses a direct free air cooling regime. The data centre contains a plurality of hot aisles 3 interleaved with a plurality of cold aisles 5 wherein each hot aisle 3 is separated from an adjacent cold aisle 5 by a rack storage area 7. Each rack storage area 7 accommodates a row of fifteen racks of IT equipment, each rack holding forty two computer servers stacked one above the other. Cooling air is provided to the cold aisles 5 by an air handling unit 9 which outputs cooling air into an air mixing chamber 13. Air from the mixing chamber 13 flows into the air supply corridor 11 through air blender 18a. The air blender 18 consists of an opening fitted with a plurality of angled baffles that passively increase the turbulence of air flowing through the blender, thereby increasing mixing. From the air mixing chamber 13, the cooling air follows a cooling air flow path from the air handling unit 9, through an air supply corridor 11, and into the cold aisles 5 through vented doors 25. The ends of cold aisles 5 are blocked by partitions 26 to entrain cooling air through the rack storage areas 7. The air supply corridor 11a is divided into a first zone lla and a second zone 1 lb, the zones separated by a cage wall and door 12 to control personnel access along the air supply corridor 11. Air is able to flow freely through the cage wall and door 12 whether the door is open or closed (the door is shown in the open position in Figure 1). The cooling air passes from the cold aisles 5 to the hot aisles 3 through the rack storage areas 7, and thus through the racks of IT equipment, thereby cooling the IT equipment. The warm air exhausted from the rack storage areas 7 into the hot aisles 3 then follows a warm airflow path into a warm air return corridor 10.

Depending on the temperature of air outside the data centre, warm air either flows from warm air return corridor 10 into warm air mixing chamber 14 via return vent 29, or out of the data centre through exhaust vents 16. Return vent 29 and exhaust vents 16 comprise adjustable dampers for controlling the amount of air from the warm air return corridor 10 that is (a) exhausted out of the data centre, or (b) recirculated into -19 -the mixing chamber 14. Also depending on the temperature of air outside the data centre, ambient air from outside the data centre enters mixing chamber 14 through intake vents 17. Intake vents 17 comprise adjustable dampers for controlling the amount of ambient air admitted into the mixing chamber 14. Also depending on the temperature of air outside the data centre, the air handling unit 9 receives air from the mixing chamber consisting of (a) ambient air from outside the data centre, (b) warm air from the hot aisles 3, or (c) ambient air from outside the data centre mixed with warm air from the hot aisles 3. Warm air mixing chamber 14 comprises outer chamber 14a and inner chamber 14b. In use, air flows from the outer chamber 14a to the inner chamber 14 b through air blender 18b.

The air supply corridor 11 is also configured to transport cooling air to a services area 15 via vented door 27. Adjacent the vented door 27 is a fire door 28 (shown in its normal open position in Figure 1). Services area 15 comprises a central personnel area located in a cold zone 15a. The personnel area is flanked on one side by an electrical switchboard storage area accommodating IT and mechanical electrical switchboards 20, and a UPS switchboard storage area accommodating IT UPS switchboard 21a and mechanical UPS switchboard 21b. The cold zone 15a of the services area is defined by a services module 2 having a primary frame 22 extending around the sides of the module 2. The UPS switchboards 21 are floor standing units positioned adjacent the primary frame 22. On the opposite side of the primary frame is a secondary frame which together with panels supported by the secondary frame forms a fire barrier 201. The fire barrier 201 separates the cold zone 15a of the services area from a hot zone 15b. The fire barrier 201 also separates the cold zone 15a from a battery room 24. The hot zone 15b of the services area 15 comprises a booster fan 23 for expelling warm air in the hot zone 15b into the mixing chamber 13.

In use, cooling air flows from the air supply corridor 11 into the cold zone 15a of the services area 15, through the UPS switchboards 21 into the hot zone 15b (via a duct not shown in Figures 1 and 2), and from the hot zone 15b back into the mixing chamber 13. The warm air from the hot zone 15b of the services area 15 is then mixed with cool air from the air handling unit 9, and returns to the air supply corridor 11 through the air blender 18a. The UPS power source connected to the UPS switchboard consists of a plurality of batteries housed in the battery room 24. The battery room 24 is provided with its own, independent, air conditioning system (not shown). It has been found that batteries must be kept at a strictly controlled -20 -temperature; a temperature that is often different to the temperatures suitable for safe and reliable operation of UPS switchboards and rack-mounted IT equipment. Accordingly, it is often advantageous to provide the battery room 24 with its own air conditioning equipment.

When the services module 2 was transported from its manufacturing location (where it was fitted with the UPS switchboards 21 and the electrical switchboards 20 as well as the vented door 27), the secondary frame of the fire barrier 201 was attached to the primary frame 22 of the services module 2. Once the services module 2 was positioned in the building intended to provide the data centre 1, the secondary frame was attached to the floor and ceiling (not shown in Figure 1) of the building below and above the services module 2, and also to the external walls 302 of the building. In addition to the secondary frame and the panels, the fire barrier 201 also includes fire dampers 203 for allowing air to pass from the cold zone 15a of the services area to the hot zone 15b. The fire dampers 203 comprise a plurality of motorised fins mounted in a frame (not shown in Figure 1). During normal operation of the data centre, the fins are kept in an open position allowing air to flow through the damper. In the event of a fire, the fins move to a closed position that prevents airflow through the damper in response to a signal received from a data centre fire control system (not shown in Figure 1). The fire barrier 201 further comprises the fire door 28, which also moves to a closed position that prevents airflow through the vented door 27 in response to a signal received from the fire control system. Yet further, the fire barrier 201 comprises another fire door 204 for allowing personnel access from the cold zone 15a of the services area to the battery room 24. Unlike the other fire door 28, this fire door 204 is normally kept in the closed position (although it is shown in its open position in Figure 1) to allow the air conditioning unit for the battery room 24 to maintain its climate independently of the climate in the cold zone 15a of the services area. Manufacturing the fire barrier 201 at an off-site manufacturing location allowed work on the fire barrier to be undertaken in a controlled environment in parallel with other construction work on site. Transporting the fire barrier 201 to site attached to the primary frame 22 of the services module provided a convenient way of transporting the fire barrier that reduced the risk of damage during handling and transit. Attaching the fire barrier 201 to the building provided a barrier with sufficient structural integrity to meet local fire regulations. In another embodiment, the fire barrier is optionally detached from the primary frame 22 -21 -of the services module 2 once the module 2 is installed in the building, thereby providing an enhanced degree of structural integrity, for example meaning that should the primary frame 22 of the module 2 be damaged by fire, collapse or distortion of the primary frame 2 should not compromise the integrity of the fire barrier 201.

Figure 2 shows an enlarged plan view of the services module 2 of the data centre 1 of Figure 1. The same reference numerals as used in Figure 1 are used in Figure 2. With the exception that the fire doors 28, 204 are shown in their open position, Figure 2 shows the services module 2 as transported from its manufacturing location to the building forming the data centre 1. In its transport configuration, the secondary frame of the fire barrier 201 is bolted to the primary frame 22 of the services module 2 with bolts (not shown) that pass through the secondary frame and are received by captive nuts (not shown) welded to the primary frame 22.

Figure 3 is a cross-sectional view of the services area 15 of the data centre of Figure 1. The same reference numerals used in Figures 1 and 2 are used in Figure 3.

As shown in Figure 3, the cold zone 15a of the services area 15 is made up of a personnel area flanked on each side by the electrical switchboard 20 and the mechanical UPS switchboard 21b. The mechanical UPS switchboard 21b is located adjacent the first side of the primary frame 22 of the services module 2. The fire barrier 201 separates the cold zone 15a from the hot zone 15b. The mechanical UPS switchboard 21b comprises a cooling air inlet 214 and a warm air outlet 215. Aligned directly above the warm air outlet 215 and spaced apart from the mechanical switchboard 21b is a duct 205 for directing warm air from the outlet 215 to the fire damper 203. The hot zone 15b comprises a booster fan for expelling air from the hot zone 15b into the mixing chamber (not shown in Figure 3). The services area 15 also comprises a temperature and humidity sensor 202 located on the ceiling of the cold zone 15a. The sensor 202 is connected to a data centre climate control system (not shown). If the climate control system determines that the temperature in the cold zone 15a exceeds a pre-determined set point, first the vented door 27 (not shown in Figure 3) is adjusted to open its vents to the greatest extent, and if those vents are already open, the speed of the booster fan 23 is increased. As shown in Figure 3, the services module 2 is positioned between a floor 303 and a ceiling 304 of the building forming the data centre 1. The services module 2 rests on the floor 303 of the building. As also shown in Figure 3, the secondary frame of the fire barrier 201 is attached to the floor 303 and to the ceiling 304.

-22 -Figure 4 shows a perspective view of the frame 1002 of a building module 1001 according to another embodiment of the invention. As shown in Figure 3, the frame 1002 defines the bottom 1003, top 1004 and sides 1005a-d of the module 1001 (1005a being the first side and 1005b being the second side).

Figure 5 shows a perspective view of the building module 1001 of Figure 4 with the frame 1010 of a fire barrier attached to the frame 1002 of the module 1001. As shown in Figure 5, the frame 1010 of the fire barrier is attached to the first and second sides of the module 1001. The frame 1010 of the fire bather comprises a plurality of upright members (a selection of which are labelled in Figure 4) attached to the frame 1002 of the module 1001. The module 1001 is also shown with a floor 1006 mounted on the bottom of the module.

Figure 6 shows a perspective view of the building module 1001 of Figures 4 and 5 in which the fire barrier comprises a plurality of panels 1011 mounted on the frame 1010 of the fire barrier. A selection of fire barrier panels 1011 are labelled in Figure 6. The fire barrier further comprises fire door assemblies 1012 and 1013. The fire door assemblies 1012, 1013 each comprise a door frame attached to the frame 1010 of the fire barrier, the door frame supporting a fire door. Not shown in Figure 6 are the fire dampers that will complete the fire barrier. The fire dampers will be installed in the positions marked 'X' in Figure 6.

Figure 7 shows a plan view of the building module 1001 and fire barrier of Figure 6. The same reference numerals used in Figure 6 are used in Figure 7. Figure 8 shows a cross-sectional view through the building module 1001 and fire barrier of Figures 6 and 7. The features of the building module 1001 also shown in Figures 4-7 are labelled with the same reference numerals as used in Figures 4-7.

In Figure 8, the building module 1001 is shown being used as a services module for a data centre, and is shown fitted with a UPS switchboard 8021 and a duct 8205 for collecting warm air exhausted by the UPS switchboard 8021. The UPS switchboard 8021 sits on the floor 1006 of the module 1001 adjacent the frame 1002 of the module on one side (in Figure 8, no vertical members of the frame 1002 are shown). The duct 8205 is mounted on the frame 1002 of the module 1001. The bottom of the duct 8205 is spaced apart from the top of the UPS switchboard 8021 by about 10 mm. The UPS switchboard 8021 comprises at its bottom an air intake opening (not shown in Figure 8) and an air exhaust opening on its top below the duct (not shown in Figure 8). The -23 -fire barrier is shown fitted with fire damper 8203 comprising a plurality of motorised fins 8300.

Figure 9 shows an enlarged detail plan view of part of the door assembly 1012 of the building module 1001 and fire barrier of Figures 6 and 7. The features of the building module 1001 also shown in Figures 4-8 are labelled with the same reference numerals as used in Figures 4-8.

Figures 10 and 11 show enlarged detail cross-sectional views of the joints between the fire barrier and the frame 1002 of the building module 1001 of Figures 68. The features of the building module 1001 also shown in Figures 6-8 are labelled with the same reference numerals as used in Figures 6-8. In Figures 10 and 11, the fire barrier frame 1010 is shown fastened to the frame 1002 of the building module 1001 by bolts 10002 and 1101. When the module 1001 is installed in a building, bolt 10001 located at the top of the fire barrier frame 1010 is used to fasten the fire barrier frame 1010 to the underside of the ceiling of the building (not shown in Figures 10 and 11). In another embodiment, the bolt 1002 attaching the fire barrier frame 1010 to the module frame 1002 can be removed to detach the fire barrier from the module 1001. During installation, the module frame 1002 at the bottom of the module 1001 is attached to the floor of the building by additional bolts (not shown in Figures 10 and 11). The fire bather frame 1010 remains attached to the bottom of the building module frame 1002 by bolt 11001, thus being attached to the floor of the building via the bottom of the module 1002. It will be appreciated that even when the fire barrier frame 1010 is attached both to the floor of the building and to the bottom of the building module frame 1002, the fire barrier frame 1010 could still be detached from the top of the building module frame 1002. With such an arrangement, attachment of the top of the fire barrier to the ceiling of the building is entirely independent of the module, thus allowing the fire barrier to remain in place should the structure of the module not retain its structural integrity in the event of a fire. As shown in Figures 10 and 11, the fire barrier panels 1011 comprise an internal insulation layer 8201c sandwiched between inner and outer facing panels 8201b and 8201a. Each of the inner and outer facing panels 820 lb and 8201a act as stiffening layers and each comprises an inner layer of plasterboard overlaid with an outer layer or vinyl coated steel. The internal insulation layer 8201 c comprises fire retardant glass mineral wool.

Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art -24 -that the invention lends itself to many different variations not specifically illustrated herein.

Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.