About Project

In the semiconductor industry, where manufacturing environments demand extremely stringent standards for temperature, humidity, and cleanliness, maintaining an efficient and stable HVAC system is crucial. 

At the Intel Vietnam factory, one of the world's leading high-tech manufacturing facilities, the HVAC system not only ensures an ideal production environment but also accounts for a significant portion of the total energy costs.

Recognizing this, from 2018 to 2023, Khoi Minh EIST Co., Ltd was entrusted with the execution of a series of EC-Motor fan upgrade projects for AHUs and CRAHs at Intel. This was a long-term campaign, demonstrating Intel's strategic vision for optimizing performance and energy savings.

• Primary Objectives: Improve ventilation system efficiency, reduce energy consumption by 30% to 60%, maintain stable airflow, and ensure strict temperature and humidity control in cleanrooms.
• Project Scope: Implementation across 27 AHU (Air Handling Units) and CRAH (Computer Room Air Handlers) systems in critical production areas and data centers.
• Executing Unit: Khoi Minh EIST Co., Ltd.

EC-Motor Fan Upgrade Project Implementation Process for HVAC Systems

HVAC System Upgrade Project Implementation Process

To ensure the success of the EC-Motor fan upgrade project for AHUs and CRAHs at Intel, Khoi Minh implemented a professional and systematic 4-step process:

1. Survey – Data Measurement: Engineers inspect the current condition and accurately measure the parameters of the existing fans, such as airflow, static pressure, total pressure, and operating current (amps). This is a crucial step to establish a baseline for selecting replacement equipment and evaluating subsequent efficiency gains.
2. Removal of Old Fans – Installation of New EC-Motors: The construction work is planned in detail to minimize downtime. The process of removing the old system and installing the new EC-Motor fans is carried out by a team of skilled technicians, strictly adhering to factory safety standards.
3. Connection to BMS Control System – Fan Speed Calibration: After physical installation, the new fans are connected to the BMS system. Automation engineers program and calibrate the fan speed to precisely achieve the desired airflow and pressure, ensuring smooth system operation.
4. Test Run – Acceptance and Handover: The system undergoes continuous test runs to check for stability. Operating parameters are remeasured and compared with initial data to confirm the HVAC energy savings efficiency. Upon meeting all standards, the project is accepted and handed over to the client with technical documentation and operating instructions.

Test Run – Acceptance and Handover

Project Implementation Stages for HVAC System Upgrade by Year

The renovation and upgrade of the HVAC system was implemented in stages, ensuring no disruption to the factory's continuous production operations.

2018 – EC-Motor Fan Upgrade for AHUs

The initial phase focused on upgrading AHUs in key production areas.

• Planning and Equipment Selection: Khoi Minh's engineering team conducted a detailed survey of each AHU, measuring the operating parameters of the existing fans. Based on the actual data and Intel's requirements, we selected the most suitable EC-Motor fan replacements, ensuring they precisely met the required airflow and pressure, while also offering flexible speed control.
• Construction and Measurement: The process of removing the old fans and installing the new EC-Motor fans was carried out carefully. After installation, parameters such as airflow, pressure, and operating current were remeasured to compare efficiency.
• Control System Check: The new fans were successfully integrated into the building management system (BMS), allowing for flexible operation in both manual on-site control and remote automatic control modes, optimizing energy usage.

2018 – Nâng cấp quạt EC-Motor cho AHU

2020 – EC-Motor Fan Upgrade for Data Center CRAHs

The data center is the heart of the factory, demanding absolute stability in temperature and humidity. Upgrading CRAHs in this area was a significant challenge.

• High Technical Requirements: Unlike AHUs, the CRAH system in the Data Center has a self-regulating fan mechanism to maintain an ideal environment. Intervention requires close coordination and precision.
• Operational Coordination: Khoi Minh's team and Intel's operations department (OPS) worked together to fine-tune the fan speeds after the EC-Motor fan upgrades. The goal was to ensure that the airflow and pressure were not only sufficient but also optimized to keep the temperature and humidity in the room within safe limits, protecting expensive server equipment.

2022 – Continued EC-Motor Fan Upgrades for AHUs

Building on the success of Phase 1, the project was further expanded to the remaining AHU systems in the factory, completing the conversion process and enhancing the ability to control airflow on a large scale. This AHU renovation phase helped to standardize technology and comprehensively optimize system performance.

2023 – Comprehensive EC-Motor Fan Renovation for AHUs and CRAHs

This was the concluding stage of the project series, involving a comprehensive renovation and the replacement of EC-Motor fans with new technology for all 27 AHU & CRAH systems.

• Total Renovation: All systems were equipped with the latest generation of EC fans, delivering superior performance and greater durability.
• Smart Control Integration: This stage went beyond just hardware replacement. Khoi Minh integrated a smart control system, enabling remote monitoring and control of the entire fan system via BMS. This gives Intel's operations team a comprehensive overview, making it easier to detect issues and optimize operations in real-time.

Pre- and Post-Renovation Performance Data

Numbers don't lie. Actual measurement data before and after the EC-Motor fan upgrade project for AHUs and CRAHs at Intel proved the superior effectiveness of the solution.

Below is a typical performance comparison table for an AHU system:

As the table shows, while still ensuring the necessary airflow for production, electrical power consumption was significantly reduced, saving from 33% to 59% depending on the system. This is an extremely impressive figure, delivering direct and sustainable economic benefits.

HVAC System Upgrade Project Implementation Process

To ensure the success of the EC-Motor fan upgrade project for AHUs and CRAHs at Intel, Khoi Minh implemented a professional and systematic 4-step process:

1. Survey – Data Measurement: Engineers inspect the current condition and accurately measure the parameters of the existing fans, such as airflow, static pressure, total pressure, and operating current (amps). This is a crucial step to establish a baseline for selecting replacement equipment and evaluating subsequent efficiency gains.
2. Removal of Old Fans – Installation of New EC-Motors: The construction work is planned in detail to minimize downtime. The process of removing the old system and installing the new EC-Motor fans is carried out by a team of skilled technicians, strictly adhering to factory safety standards.
3. Connection to BMS Control System – Fan Speed Calibration: After physical installation, the new fans are connected to the BMS system. Automation engineers program and calibrate the fan speed to precisely achieve the desired airflow and pressure, ensuring smooth system operation.
4. Test Run – Acceptance and Handover: The system undergoes continuous test runs to check for stability. Operating parameters are remeasured and compared with initial data to confirm the HVAC energy savings efficiency. Upon meeting all standards, the project is accepted and handed over to the client with technical documentation and operating instructions.

Benefits After HVAC System Renovation Projects

The 5-year project series has brought significant and comprehensive benefits to the Intel factory:

• Superior Energy Savings: Reduced electricity consumption for AHU and CRAH systems by 33% to 59%, directly cutting a significant monthly operating cost.
• Improved Cleanroom Environment: The flexible control system helps maintain more stable temperature and humidity in the cleanroom, enhancing the quality of the production environment and minimizing product risk.
• Increased System Lifespan: EC-Motor fans operate more quietly, with less vibration and heat generation compared to belt-driven fans, thereby reducing wear and tear and increasing the lifespan of the entire AHU & CRAH system.
• Environmental Protection: Reduced electricity consumption means reduced greenhouse gas (carbon) emissions, demonstrating Intel's commitment to sustainable development and green manufacturing.
• HVAC System Optimization: The upgrade makes Intel's HVAC system smarter, easier to monitor and control, contributing to more efficient Intel AHU maintenance in the future.

Lợi ích sau các dự án nâng cấp quạt EC

Conclusion

The EC-Motor fan upgrade project for AHUs and CRAHs at Intel from 2018 to 2023 is a prime example of the successful application of modern technology to optimize industrial systems. The project not only completed on schedule but also achieved energy savings that far exceeded initial expectations.

Thành công này một lần nữa khẳng định năng lực chuyên sâu và kinh nghiệm dày dặn của Khoi Minh trong lĩnh vực tư vấn, thiết kế và thi công các giải pháp cải tạo hệ thống HVAC phức tạp, đặc biệt là trong các môi trường công nghệ cao đòi hỏi tiêu chuẩn khắt khe nhất.

Contact for Solution Consultation

If your factory is looking for a solution to reduce energy costs and improve HVAC system performance, don't hesitate!

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Let Khoi Minh partner with your business in maintaining equipment performance and optimizing operating costs.

📞 Hotline: 0.968.37.38.39
📧 Email: info@khoiminh.com

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