Failure Analysis of Liquid Cooling Setup for Hyperscale Datacenter Infrastructure

Abstract Air-assisted liquid cooling (AALC) has emerged as a preferred cooling solution for data centers housing traditional air-cooled server racks, owing to its straightforward integration with existing infrastructure. However, the rising power demands of AI hardware (30-100kW per rack) and its variable computational loads generate unprecedented heat levels that challenge system reliability and uptime. Through long-term reliability testing of AALC systems, we identify and analyze unique failure mechanisms associated with liquid cooling implementations. This paper presents our findings on system vulnerabilities, details the failure analysis methodology, establishes root causes, and outlines the corrective measures implemented to enhance AALC system reliability in high-performance computing environments.