What should I test before upgrading the old system to ULPA? Air volume, residual pressure and on-site interface

Upgrade old systemBefore installing the ULPA filter , the existing air volume, available pressure, operating settings and interface status should be measured to clarify the problems and upgrade goals of the original system. Only knowing the grade of the old filter element makes it impossible to judge whether modification is feasible. The most common misunderstanding when upgrading an old system is to regard it as 'replacing a higher-grade filter element': the original fan, box, and air duct remain unchanged, but only the filter is upgraded. An increase in level is usually accompanied by an increase in resistance. The original fan residual pressure may not be enough to maintain the air volume, and the system performance will decline after the upgrade. What you need to do before upgrading is not selection, but evaluation - first measure the status of the original system clearly. Aili Industry isIn the HEPA/ULPA filter modification project, the changes in working points after the upgrade can be evaluated based on the actual measured data of the original system.FFU fan filter unit andThe speed adjustment capability of the fan filter unit on the EFU equipment side can compensate for the air volume after the resistance changes, allowing the upgrade plan to be based on data.

1. Record the baseline before transformation: air volume, pressure difference, operating mode and regional performance

Measure the air volume, pressure difference and necessary regional performance under the specified operating mode to indicate the pre-filtration and equipment status to avoid misattributing the original fault to the new filter element.

The baseline data before the transformation is the reference for judging whether the upgrade is effective. If the original system itself has insufficient air volume, blocked return air or sealed bypass, these problems still exist after upgrading the filter, but they may be attributed to the new filter element. Aili Industry isIn the ULPA ultra-high efficiency filter renovation project, it is recommended to first measure the air volume, pressure difference and regional performance according to the original operating mode, and record the pre-filtration status and equipment operation status.The FFU computer group control system can record partition operating parameters as a baseline. Only when the baseline is clear can the comparison after upgrade be meaningful. The relationship between levels and filtering requirements can be found inISO cleanliness level comparison。

2. Check the fan and structural margin: curve, speed adjustment capacity and installation space

Collect curves and speed adjustment capabilities, check the resistance, thickness, sealing and inspection space of the new filter element, and map the actual interface if necessary.

Turbine margin is key to upgrade feasibility. The operating point of the original fan under the resistance of the old filter element may have been close to the steep section of the curve. After upgrading to the ULPA with higher resistance, the operating point moves in the direction of small air volume, and the air volume may decrease more than expected. In the upgrade evaluation, Aili Industrial calculates the working points based on the original fan curve and the new filter element resistance data.The FFU fan filter unit supports EC DC speed regulation, which can be compensated by speed regulation after the resistance rises.The fan filter unit at the EFU equipment end can be rechecked according to the machine back pressure. In terms of structure, the thickness, sealing form and detection space of the new filter element may be different from the original system.Non-standard ULPA filter projects can be mapped according to the original interface to confirm the adaptation plan. For working point calculation method, please refer toULPA ultra-high efficiency filter FAQ and selection guide。

3. Use pilot verification and then expand: representative modules should be confirmed first and then upgraded in batches

Confirm the air volume, power, noise and integrity of representative modules, and then formulate batch upgrade plans and maintenance arrangements.

Upgrading old systems often involves multiple devices or multiple areas, and the risk of replacing them all at once is higher. First select a representative module for piloting, confirm the upgraded air volume, power, noise and sealing status, and then adjust the plan based on the pilot results, which can reduce the overall transformation risk. Aili Industry isIn the HEPA/ULPA filter modification project, pilot verification can be done first based on representative modules.The FFU computer group control system records the operating parameters of the pilot modules and compares them with the baseline before the transformation. After confirmation of feasibility, batch upgrades and spare parts plans will be arranged. For pilot verification methods, please refer toHEPA FAQs and Selection Guide。

4. When the air volume of the original system is close to the lower limit, it cannot be assumed that there is still enough air supply after the upgrade.

When the air volume of the original system is close to the lower limit, the fan capacity should be checked first. Do not default to the fact that there is still enough air supply after changing to a higher level. If the air volume margin of the old system is already very small in the original state, the increase in resistance after the upgrade will further reduce the air volume, which may be lower than the process requirements.

During the transformation assessment, Aili Industrial will first confirm the air volume margin of the original system.FFU fan filter unit andThe fan filter unit on the EFU equipment side can recalculate the working point according to the upgraded resistance. When the margin is insufficient, the problem can be solved by adjusting the speed, adjusting the filter area or changing the fan configuration, instead of upgrading first and then discovering the problem. For margin evaluation before transformation, please refer toFFU FAQ and technical support。

5. Related questions and answers

Should I upgrade to ULPA if the original system’s cleanliness is not up to standard?
It is also necessary to investigate the pollution sources, bypasses and airflow organizations. Upgrading the level is not the solution to all problems.

Only knowing the grade of the old filter element, can we judge whether it can be upgraded?
cannot. The air volume, pressure difference, fan curve and interface status of the original system are also needed to determine whether the upgraded working point meets the requirements.

Does upgrading the old system need to be piloted first?
It is recommended to pilot representative modules first to confirm the air volume, power, noise and sealing status before upgrading them in batches.

6. Related articles

ULPA ultra-high efficiency filter FAQ and selection guide

FFU computer group control system

FFU FAQ and technical support

HEPA FAQs and Selection Guide

7. Key points for selection and acceptance inspection

8. Product matching and technical support from Aili Industrial

Aili Industry isIn the HEPA/ULPA filter modification project, the changes in working points after the upgrade are evaluated based on the measured data of the original system.FFU fan filter unit andThe speed adjustment capability of the fan filter unit on the EFU equipment side can compensate for the air volume after the resistance changes. Before transformation, it is recommended to measure the air volume, pressure difference and regional performance according to the original operating mode.The FFU computer group control system records partition operating parameters as the baseline; the upgrade evaluation calculates the working points based on the original fan curve and new filter element resistance data.Non-standard ULPA filter projects can be mapped according to the original interface to confirm the adaptation plan.The ULPA ultra-high-efficiency filter transformation project can be pilot verified based on representative modules first, and then batch upgrades and spare parts plans can be arranged after confirmation. When the air volume of the original system is close to the lower limit, the margin must be confirmed first, and the solution can be solved by adjusting the speed, adjusting the filter area, or changing the fan configuration. Provide process objectives, installation drawings, operating conditions and acceptance requirements, and can further communicate ULPA standard specifications, non-standard interfaces, samples and batch matching. The specific parameters and test range are based on the confirmed model and technical documents.