Health and Insurance Risks of Immersion Cooling in Data Centres

Immersion liquid cooling in data centres is a relatively new concept that involves submerging electronic components in a thermally conductive, electrically insulating (dielectric) liquid, offering superior cooling capacity and energy efficiency for high-density computing environments.

While this technology provides significant operational benefits, it also introduces unique health and safety challenges that data centre operators must address to protect personnel and equipment. These range from electrical risks to toxic gas exposure and fluid-related concerns, which require proactive management. At Price Forbes, we don’t just place risk, we help clients manage it. This Bulletin is aimed at helping data centre operators identify four key risks, ways to mitigate these risks and how to manage discussions with insurers.

Key risk features and risk recommendations

Electrical hazards

Risk: The proximity of dielectric cooling fluids to live electrical components increases the potential for electrical accidents. Although the fluids are non-conductive, improper insulation or system failures could create hazardous conditions for personnel working with submerged servers.

Actions to mitigate:

• Perform regular maintenance and inspections to ensure the ongoing integrity of electrical systems.
• Implement robust insulation and isolation techniques to separate live components from accessible areas.
• Perform regular maintenance and inspections to ensure the ongoing integrity of electrical systems.

Toxic gas generation

Risk: An arc flash, a sudden and intense release of electrical energy through the aircon occur in immersion cooling systems, potentially generating hydrogen fluoride (HF), a highly toxic gas. Exposure to HF can lead to severe health issues, such as respiratory damage and chemical burns.

Actions to mitigate:

• Prevent arc flashes by installing arc-resistant equipment, ensuring proper grounding, and using overcurrent protection devices.
• Develop and rehearse emergency response protocols specific to HF exposure, including evacuation plans and first aid procedures.
• Ensure adequate ventilation to disperse any potential gas buildup, particularly in enclosed data centre spaces.

Fluid-related hazards

Risk: The dielectric fluids used in immersion cooling may pose health and environmental risks. Some fluids could be toxic if ingested or upon skin contact, while others might be flammable or contribute to long-term environmental pollution (e.g., “forever chemicals” that persist in the environment). Spills can also create slippery surfaces, heightening the risk of falls.

Actions to mitigate:

• Select cooling fluids with lower toxicity and reduced environmental impact, prioritising safer alternatives where possible.
• Establish proper handling and storage procedures, including the use of personal protective equipment (PPE) such as gloves and goggles for workers.
• Develop and implement spill response plans, maintaining good housekeeping practices to clean up spills and prevent slip hazards.
• For two-phase immersion cooling systems (where the fluid evaporates), ensure proper sealing and vapor management to minimise inhalation risks.

Structural risks

Risk: Immersion cooling systems are significantly heavier than traditional air-cooled setups due to the weight of the liquid, with some configurations adding hundreds of kilograms per rack. This additional mass can strain data centre floors, potentially leading to structural failures or accidents during installation.

Actions to mitigate:

• Perform structural analyses to confirm that the data centre floor can support the added weight of immersion cooling equipment.
• Develop safe transport and installation plans to prevent accidents during equipment setup or relocation.

Importance of training

Comprehensive training is a cornerstone of safe immersion cooling operations. All personnel involved in the operation and maintenance of these systems should receive:

• Education on the specific risks associated with immersion cooling.
• Instruction on safe fluid handling and emergency response procedures.
• Regular safety drills to reinforce preparedness and response capabilities.
• Well-trained staff are critical to minimising risks and maintaining a secure working environment.

Insurance implications

It is vital to be proactive with your insurers, ensuring that they fully understand your operations and the changes you’re proposing. This eliminates surprises when it comes to claims and provides comfort to management and your investors. Your insurers may very well assist in providing their own risk management recommendations.

Our recommendations

1. Consider higher Employers Liability / Workmen Compensation insurance protection by reviewing your insurance Limits. In the UK, for example, we recommend that data centre customers insure up to £20m minimum.
2. Be aware of PFAF (perfluoroalkyl substances) exclusions in Liability insurance policies. This exclusion can often be removed if a data centre can demonstrate the highest levels of risk management.

Making history with our clients

We’ve spent over a century helping clients embrace complexity and push for progress. Immersion liquid cooling is just the latest chapter. With the right strategy, it’s a story of opportunity, not just risk.