How to calculate the annual power consumption of FFU? Calculation of power and running time by mode
Why can’t we multiply the nameplate power by the time of year?
In FFU energy saving evaluation and operating cost accounting, a common practice is to multiply the nameplate maximum power by the number of operating hours throughout the year to obtain the annual power consumption. This algorithm looks simple, but the results often deviate from reality.
In actual operation, FFU usually does not operate at full capacity throughout the year. The clean room may be divided into different operating states such as production mode, duty mode, and shutdown mode. In different modes, the FFU rotation speed is different and the input power is also different. If the calculation is based on the nameplate maximum power, the actual energy consumption will be overestimated, and it is not conducive to comparing the actual effects of different control schemes and energy-saving measures.
A more reasonable way is to calculate the actual input power and operating time of each operating mode separately, and then add them up to get the annual power consumption. Aili Industrial has complete production capabilities in FFU complete machines and control systems, and can provide power data under different control methods to help projects with energy consumption accounting. For information on the FFU complete machine and control configuration, please refer toAili Industrial FFU fan filter unit。
Basic formula for calculating annual electricity consumption
The basic calculation method of FFU annual power consumption is: the input power of each mode is multiplied by the number of operating hours of the mode throughout the year, and then the results of all modes are added.
If the project has multiple operating modes, the power and operating time of each mode can be listed separately. For example, production mode, duty mode, weekend mode, and holiday mode. The power of each mode can be obtained through actual measurement or manufacturer data, and the running time is determined according to the production plan and operation arrangement.
For projects with multiple FFU units, the total power consumption can be obtained by multiplying the annual power consumption of a single unit by the number of units. If the FFU operating modes of different regions or different models are different, they should be calculated separately by partition or model.
What value should the input power take?
The input power should be the active power of the FFU under actual operating conditions, not the motor nameplate power or fan shaft power. The input power of the FFU complete machine includes the consumption of fans, motors, controllers and other electrical components. Under different control methods and different speeds, the input power will change.
If the project uses DC FFU or EC fans, the input power usually varies with rotation speed. If AC FFU is used with voltage regulation or frequency control, the power change characteristics will be different. For group control systems, the set speeds of different zones may be different, and the power should also be recorded in different modes.
If the manufacturer provides a power curve or power data at different speeds, it can be used directly. If not, you can use a power meter to measure it on site and record the input power in different modes. Regarding the impact of control methods on power, please refer toFFU/EFU group control touch screen controller andFFU computer group control system understands different control schemes.
How to determine the running time
The running time should be determined based on the actual running plan of the project. It is necessary to clarify the number of production days throughout the year, the number of production hours per day, duty mode operating time, downtime and maintenance time. If the project has seasonal changes or order fluctuations, it can be estimated based on a typical operating plan or calculated based on scenarios.
The running time is not simply 8760 hours throughout the year. If the FFU switches to duty mode after production ends, the power and duration of the duty mode need to be calculated separately. If some areas are shut down during non-production hours, the downtime should not be included in power consumption.
For clean rooms with continuous production, the FFU may run all year round, but the rotational speed may be different in different seasons or different production stages. The running time and power mode should be determined based on the actual situation.
An example of sub-model accounting
Assume that a project has 1,000 FFUs, divided into two operating modes. In production mode, the input power of a single unit is 80 watts and it can operate for 4,000 hours throughout the year. In duty mode, the input power of a single unit is 40 watts and it can run for 3,000 hours throughout the year. The rest of the time is downtime and maintenance.
Annual power consumption in production mode: 1,000 units times 80 watts times 4,000 hours, which equals 320,000 kilowatt hours. Annual power consumption in duty mode: 1,000 units times 40 watts times 3,000 hours, which equals 120,000 kilowatt hours. The total annual electricity consumption is approximately 440,000 kWh.
If calculated based on the nameplate maximum power of 100 watts multiplied by 8,760 hours, the result is approximately 876,000 kilowatt hours, which is significantly higher than the model-based calculation result. This example illustrates that operating mode and duration have a greater impact on annual power consumption.
In actual projects, calculations should be based on measured power and actual operation plans, and assumptions should be recorded.
What factors will affect the accounting results?
The annual electricity consumption accounting results are affected by many factors. FFU input power changes with rotation speed and filter resistance. When dust accumulates in the filter, the resistance rises. If the FFU adopts constant speed control, the power may change; if constant air volume control is adopted, the power may increase as the resistance rises. Changes in operating modes and production schedules can alter run times. Ambient temperature and control methods also affect electrical component efficiency.
Therefore, annual power consumption accounting is not a one-time number, but an estimate that changes with operating conditions. It is recommended to clarify the assumptions during calculation and revise them based on actual data after operation.
Issues that should be confirmed in advance during project communication
During the FFU energy consumption accounting and energy saving assessment stage, it is recommended to confirm the following with the manufacturer: input power data at different speeds or modes; the impact of control methods on power; the power change trend after dust accumulation on the filter; whether the group control system supports sub-mode operation and energy consumption recording; power test methods and conditions; whether the running time assumption is consistent with the actual project; whether energy consumption calculation support is provided.
If you are doing FFU annual power consumption accounting, you can visitAili Industrial FFU fan filter unit understands the complete machine and control configuration. You can also contact Aili Industrial to obtain power data support under different control methods.
in conclusion
The annual power consumption of FFU should be calculated separately based on the actual input power and operating hours of each operating mode and then added together. The nameplate maximum power multiplied by the time of year can only represent specific assumptions and cannot represent actual operating energy consumption. Input power, operating time and operating mode are the main factors that affect the accounting results and should be determined based on the actual conditions of the project.
Aili Industrial has complete production capabilities in FFU complete machines and control systems, and can provide power data under different control methods to help projects with energy consumption accounting and energy saving assessment. If you need to know more about FFU energy-saving configuration, you can visitAili Industrial FFU fan filter unit , you are also welcome to contact Aili Industrial for project support.
