Sutter Hospital Vane-Axial Conversion to HUNTAIR FANWALL TECHNOLOGY®

Mass & Energy We move and condition air for many reasons. In a hospital the air we deliver is to provide: Heating and cooling for comfort Clean environments We often forget that the air we breath and condition has significant mass. (STP .075#/CuFt ). With Sutter Hospital we are moving 140,000 CFM or 10,500 pounds per minute. Our success in the Sutter Hospital project was the result of minimizing the work required to move this mass of air. This was done by: Reducing the velocity through components Eliminating Sound Attenuation Eliminating the acceleration and deceleration of the mass of air Elimination / minimization of system effect

We move and condition air for many reasons. In a hospital the air we deliver is to provide:

Heating and cooling for comfort

Clean environments

We often forget that the air we breath and condition has significant mass. (STP .075#/CuFt ). With Sutter Hospital we are moving 140,000 CFM or 10,500 pounds per minute.

Our success in the Sutter Hospital project was the result of minimizing the work required to move this mass of air. This was done by:

Reducing the velocity through components

Eliminating Sound Attenuation

Eliminating the acceleration and deceleration of the mass of air

Elimination / minimization of system effect

Important Equations Our success was not creating new laws or breaking old laws, but managing the mass with careful attention to the laws that exist. The following equations are simple and applicable to the work and end results that were achieved. TOTAL PRESSURE = SP+ VP AIR HP = CFM x TP x .000158 BHP = CFM x TP x .000158 FAN EFFICIENCY POWER = CFM x TP x .000158 FAN EFFICIENCY x MOTOR EFFICIENCY

Our success was not creating new laws or breaking old laws, but managing the mass with careful attention to the laws that exist. The following equations are simple and applicable to the work and end results that were achieved.

TOTAL PRESSURE = SP+ VP

AIR HP = CFM x TP x .000158

BHP = CFM x TP x .000158

FAN EFFICIENCY

POWER = CFM x TP x .000158

FAN EFFICIENCY x MOTOR EFFICIENCY

All Fans Might be Rated by AMCA BUT Applications and Rating are Far Different! All fans are rated by or in accordance with AMCA. Ultimate goal is highest static efficiency and subsequent system efficiency. However most fans are not applied in the same fashion as they are are lab tested and catalogued, resulting in significant system effect. EXCEPT HUNTAIR FANWALL TECHNOLOGY where fans are lab tested and rated exactly as they are applied in the units, resulting in spectacular projects and field results.

All fans are rated by or in accordance with AMCA.

Ultimate goal is highest static efficiency and subsequent system efficiency.

However most fans are not applied in the same fashion as they are are lab tested and catalogued, resulting in significant system effect.

EXCEPT HUNTAIR FANWALL TECHNOLOGY where fans are lab tested and rated exactly as they are applied in the units, resulting in spectacular projects and field results.

Sutter Hospital FANWALL TECHNOLOGY Goal To replace the existing Vane Axial system with FANWALL while the system is in operation. HUNTAIR worked very closely with the general contractor FM BOOTH to achieve this goal. Provide N+2 redundancy Provide 100% design flow (currently at 80%) Reduce power consumption by 40%

To replace the existing Vane Axial system with FANWALL while the system is in operation. HUNTAIR worked very closely with the general contractor FM BOOTH to achieve this goal.

Provide N+2 redundancy

Provide 100% design flow (currently at 80%)

Reduce power consumption by 40%

Stage 1 – Review Existing The existing system incorporated a large single Vane- Axial fan with two opposing inlets. The inlets consisted of pre-filters, cooling coils, and a high configured inlet attenuation package. The discharge section of the fan consisted of a velocity pressure regain cone blowing directly into a splash plate to break the velocity prior to blowing into a HEPA filter bank. Issues: Single fan supplying approximately 90% of the Hospital No redundancy Limited ability to replace motor and fan when failure occurs. Due to velocity pressure losses with the system, improper application of Velocity Pressure regain, and significant system effect, the system was only delivering 80% of design capacity. Solution HUNTAIR FANWALL TECHNOLOGY® Converting coils from Draw through to Blow through design

Issues:

Single fan supplying approximately 90% of the Hospital

No redundancy

Limited ability to replace motor and fan when failure occurs.

Due to velocity pressure losses with the system, improper application of Velocity Pressure regain, and significant system effect, the system was only delivering 80% of design capacity.

Solution

HUNTAIR FANWALL TECHNOLOGY®

Converting coils from Draw through to Blow through design

Stage 2 – Demolition The existing mechanical room allowed for little room for installation and service of components. To achieve the goal to convert the existing system to FANWALL TECHNOLOGY, two banks of 70,000 CFM had to be installed, one on each side of the existing filter banks. As shown in the above diagram, there was sufficient space on the right hand inlet, but the left hand inlet was block by an existing supply duct. Booths’ sheet metal crew had to demolish the existing ductwork and tap into the existing riser to reroute the duct to the floor to allow for the left hand bank of fans to be installed.

The existing mechanical room allowed for little room for installation and service of components. To achieve the goal to convert the existing system to FANWALL TECHNOLOGY, two banks of 70,000 CFM had to be installed, one on each side of the existing filter banks.

Stage 3 – Install FANWALL Cells There was no margin for error. Both the left hand banks of FANWALL cells were installed while the system was still in operation. As seen in the diagram, part of the solution required building a structural stand over the newly relocated supply ductwork that was installed in Stage 2. After both banks of FANWALL TECHNOLOGY cells were installed, complete with new VFDs, the banks were energized to validate performance and to verify the ability of the hospital’s facility management system to communicate with the new electrical drives.

There was no margin for error. Both the left hand banks of FANWALL cells were installed while the system was still in operation. As seen in the diagram, part of the solution required building a structural stand over the newly relocated supply ductwork that was installed in Stage 2.

Stage 4 – Sheet Metal Enclosures After both banks of fan cells were installed and performance was validated from both the controls and power side, sheet metal enclosures were constructed between each bank of cells to the cooling coils that were part of the initial project construction. The goal to reduce velocities required a sheet metal enclosure to be built around the existing vane axial fan. This enclosure connected the plenum down stream of the coils to the plenum housing the HEPA filters.

After both banks of fan cells were installed and performance was validated from both the controls and power side, sheet metal enclosures were constructed between each bank of cells to the cooling coils that were part of the initial project construction.

Stage 5 – Demolish Internal Components The FANWALL cells were selected to meet the current system requirements. This included the air and static pressure that the hospital needed to be delivered into the supply duct as well as all the internal pressure loss components that the initial design imposed upon the system. After the system was successfully operational with the FWT system in a blow through configuration, delivering 100% performance expectations, Booths’ sheet metal workers were able to remove internal system loss components. These included: Elimination of inlet sound attenuator that attenuated the sound but also accelerated the air to approaching 9,000 foot per minute. Opened the space around the vane axial fan resulting in a decrease of velocity down under 1,000 foot per minute. Eliminated the velocity head splash plate that was installed directly down stream of the original vane- axial fan.

The FANWALL cells were selected to meet the current system requirements. This included the air and static pressure that the hospital needed to be delivered into the supply duct as well as all the internal pressure loss components that the initial design imposed upon the system.

After the system was successfully operational with the FWT system in a blow through configuration, delivering 100% performance expectations, Booths’ sheet metal workers were able to remove internal system loss components. These included:

Elimination of inlet sound attenuator that attenuated the sound but also accelerated the air to approaching 9,000 foot per minute.

Opened the space around the vane axial fan resulting in a decrease of velocity down under 1,000 foot per minute.

Eliminated the velocity head splash plate that was installed directly down stream of the original vane- axial fan.

Conversion End Result Initial design: Zero Redundancy 260 AMP, 460V, 3 Phase Consumption FANWALL TECHNOLOGY conversion: Four Fan Redundancy 148 AMP, 460V, 3 Phase Consumption 112 AMP Reduction = Approximately $77,000 in energy savings per year The above results are delivering the same amount of air at the same static pressure that the initial vane axial design was providing to the hospital. Current power consumption is higher than above performance because the hospital can and does now provide 100% of the air that the initial design was unable to deliver. This performance can also be met with two fans down.

Initial design:

Zero Redundancy

260 AMP, 460V, 3 Phase Consumption

FANWALL TECHNOLOGY conversion:

Four Fan Redundancy

148 AMP, 460V, 3 Phase Consumption

112 AMP Reduction = Approximately $77,000 in energy savings per year

Performance Evaluation The performance of the system resulted in over a 40% reduction in consumed power while delivering the exact same amount of air and static pressure to the supply duct. Review the formulas below, the reduction came in the form of a static pressure reduction. This reduction was achieved through: Elimination of static pressure resulting from the removal of existing sound attenuation Reduction in velocity (acceleration of mass) in the attenuator, inlet bell, annular space of the vane-axial fan, and regain cone Elimination of pressure loss associated with fan discharge splash plate Elimination of system effect associated with the splash plate located immediately downstream of the fan discharge

The performance of the system resulted in over a 40% reduction in consumed power while delivering the exact same amount of air and static pressure to the supply duct. Review the formulas below, the reduction came in the form of a static pressure reduction. This reduction was achieved through:

Elimination of static pressure resulting from the removal of existing sound attenuation

Reduction in velocity (acceleration of mass) in the attenuator, inlet bell, annular space of the vane-axial fan, and regain cone

Elimination of pressure loss associated with fan discharge splash plate

Elimination of system effect associated with the splash plate located immediately downstream of the fan discharge

Graphic Unit Velocity Representation Internal Unit Velocity in Feet per Minute Airway Length of unit - Feet Air enters prefilters and coils Air enters supply ductwork

Foot Note – Vane-Axial Ratings Vane-Axial fans just like plenum fans are designed to move air against the system resistance components (SP). But in addition they are rated with the velocity pressure component that is created in the annular space between the hub and the barrel or casing. Vane-Axial fans as rated are very efficient fans. The efficiency of the vane-axial fan is directly related to the ability to convert the velocity pressure component of the fan into usable static pressure. However, more often than not, the fan is applied in a manner that is not consistent with the manufacturers catalogue ratings. Because of this, significant system effects result in the performance of the fan and the inability to recognize velocity pressure regain. When working with, or competing against systems incorporating vane axial fans, closely evaluate the manufactures installation documents to identify potential misapplication. Static Pressure + Velocity Pressure Total Pressure

Vane-Axial fans just like plenum fans are designed to move air against the system resistance components (SP). But in addition they are rated with the velocity pressure component that is created in the annular space between the hub and the barrel or casing.

For More Information Please Contact: HUNTAIR, INC. / CLEANPAK INTERNATIONAL, INC. Corporate Office 11555 SW Myslony Street Tualatin, OR 97062 USA • 503-639-0113 www.huntair.com Huntair and Cleanpak are part of the CES Group Companies, and is affiliated with the following air conditioning manufacturers: Eaton-Williams Group, Ltd. • Governair Corporation • Mammoth, Inc. • Mammoth China, Ltd. • Temtrol, Inc. • Venmar CES, Inc. • Ventrol Air Handling Systems, Inc. • WEBCO, Inc. Each company is a separate and distinct legal entity. Huntair ® is a registered trademark of Huntair, Inc. Cleanpak ® is a registered trademark of Cleanpak International, Inc. CES Group TM is a trademark of CES Group, Inc. FANWALL TECHNOLOGY ® and FANWALL ® are registered trademarks of Huntair, Inc. US Patent No’s 7,137,775 B2 and 7,179,046 B2