A Case Study : Epoch HVLS 18-ft Fan By Falco eMotors Inc.
Report No. 040220-01
Problem:
- Elkayem Auto Ancillaries has become a well-known Industrial Equipment Shop in Hosur where it has processing, forging, machining as well as assembly facilities. The facility itself has low insulation.
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The company realized that hot working conditions in the summer and cold conditions in the winter diminishing employee comfort levels which affects productivity.
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Also, heat, moisture, and stagnant air are the most frequently encountered problems in the production shop, which has a very negative impact on working conditions.
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The company has decided to install an industrial HVLS fan that can provide some relief in this case.
Solution:
- Epoch 2.0, 18-ft 02 Fans was installed with the following specifications ;
- Motor: Epoch 2.0;
- Coverage Area: 15000 Sq. Ft. (1393 Sq. m);
- Speed: 75 RPM;
- Peak Power: 1.1kW/1.5 hp;
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Epoch 2.0-18 ft diameter five-bladed fan is the best one for air circulation and it is more efficient in power consumption
Site Survey:
A site survey is mandatory before any HVLS fan recommendation. The survey revealed the following dimensions:
- Total Area: 150 ft X 60 ft = 9,000 Sq. ft.
- Floor to Ceiling Distance: 25 to 28 ft,
- By a rule of thumb distance/1.5 gives us the approximate fan diameter.
- In this case, we chose to go with a 18-ft fan.
Fan and Coverage Area:
Test Reports:
Three test reports are collected for each fan installation as follows:
- Power Consumption Report;
- Input Current Report;
- Air Flow Report.
Those reports are shown for this site:
Power consumption report captures the real as well as apparent power. Epoch HVLS fans are the only fans in the world to have active power factor correction and unity power factor. Therefore the Watts (Real Power) and VARs (the apparent power) are almost the same. The power has been captured at 35, 45, 55, 65 and 75 RPM. Power drawn at those speeds are 280, 330, 499, 877 and 1020W respectively. The chart above also shows trend lines generated using Excel for real and apparent power to take into account any measurement errors as fan power consumption can be modeled by well known equations.
The input current is also measured at 35, 45, 55, 65 and 75 RPM. Input current is recorded as 0.62, 1.35, 2.4, 3.96 and 4.7A respectively. The input voltage varied from 230 to 240V during the measurement.
The airflow is measured from the center of the fan and is recorded at every 3-ft distance. Values were recorded upto 30-ft from the center of the fan. The values were respectively, 216, 236, 452, 551, 689, 590, 452, 346 ft/min at distances of 3,6,9,12,15,18,21, and 24-ft respectively.
Estimated Yearly Savings while Using Epoch HVLS Fans
Epoch 18-ft fan was compared against Indian HVLS fan Manufacturer. Based on their data sheet, daily, monthly and yearly power consumption and costs were calculated. An Epoch HVLS fan will save the end user anywhere from $1,059 to $4,475 per year over any competitive brands because of its unique technology.
Finished Installation:
Above is the video of the finished installation.