energy savings calculator_pump and fan vfd

7/23/2019 Energy Savings Calculator_pump and Fan VFD

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Energy Savings Calculator - Pump and Fan VFD RetroIntroduction

Fan Analysis Instructions

Step 1 Enter fan motor information (motor hp and efficiency from motor nameplate or other docu

Step 2 Estimate motor load factor, or use default load factor (80%).

Step 3 Determine fan motor full load kW - the analysis will e ased on a calculated !alue determ

Step 4 Enter the fans annual hours of operation

Step 5 "elect e&istin' and proposed control systemshe control type selection determines which standard part load p

he cur!es were de!eloped from data otained y measurin' the

https$sa!e-ener'y-now.or'E3toolsDocumentspumps5"D%4

Step 6 "elect annual load profile

Savings Calculation Metod

he results of the analysis are presented in the tale and 'raphs to the ri'ht of the input s

nnual hours of operation (column 3) for each of the pump load

he e&istin' (column 6) and proposed (column 7) full load powe

he e&istin' (column ) and proposed (column 2) pump power ihe e&istin' (column +) and proposed (column ") annual ener'y

he total annual ener'y sa!in's is the sum of difference etween

Pump Analysis Instructions

Step 1 Enter pump motor information (motor hp and efficiency from motor nameplate or other doc

Step 2 Estimate motor load factor, or use default load factor (80%).

Step 3 Determine pump motor full load kW - the analysis will e ased on a calculated !alue dete

Step 4 Enter the pumps annual hours of operation

Step 5 "elect e&istin' and proposed control systemshe control type selection determines which standard part load p

he cur!es were de!eloped from data otained y measurin' th

Step 6 "elect annual load profile


he results of the analysis are presented in the tale and 'raphs to the ri'ht of the input s

nnual hours of operation (column 3) for each of the pump load

his calculator is desi'ned to pro!ide sa!in's estimates for 5D fan and pump installations. he tool canwith 'eneric load profiles and estimated full load motor loadin'.his tool has three specific calculation pa'es$#) VFD Fan Analysis - fan applications

4) VFD Pump Analysis - +ump applications where system flow will !ary throu'hout the year :) !rottle Valve Analysis - +ump applications where system flow will remain constant and a 5D is ei

<f Full "oad (#00% flow) spot Po#er measurements ha!e een t

<f Full "oad (#00% flow) spot mperage measurements are a!ai

<f annual load profile is $no#n from site metered data or site s

<f annual load profile is not $no#n, select a 'eneric load profile i



<f annual load profile is $no#n from site metered data or site s

<f annual load profile is not $no#n, select a 'eneric load profile i



he e&istin' (column 6) and proposed (column 7) full load powe

he e&istin' (column ) and proposed (column 2) pump power i

he e&istin' (column +) and proposed (column ") annual ener'y

he total annual ener'y sa!in's is the sum of difference etween

!rottle Valve Instructions

Step 1 Enter pump motor information (motor hp and efficiency from motor nameplate or other docStep 2 Estimate motor load factor, or use default load factor (80%).

Step 3 Determine pump motor power - the analysis will e ased on a calculated !alue determin

<f no full load spot measurements are a!ailale, estimate motor lo

Step 4 Enter the pumps annual hours of operation

Step 5 Determine e&istin' system flow$

<f only the e&istin' !al!e position is known select >nown 5al!e +


he results of the analysis are presented in the tale to the ri'ht of the input section. he

he e&istin' system power is determined from the measured !aluhe throttlin' de!ise mo!es the system cur!e to the left and the p

System % Flo# alculated from either the !alue in cell

E&isting System - Full "oad Po#er alculated from throttle !al!e re'ressi

Proposed System - Full "oad Po#er alculated from 5"D re'ression cur!

he total annual ener'y sa!in's is the sum of difference etween the annual ener'y usa'



<f the system flow is $no#n from site metered data or spot me



it

ented source)

ined from "tep #, or the user may input full load kW ased on field measurements$

rformance cur!e will e used in the calculations. ll part load cur!es were taken from the *onne!ille +ower d

operatin' characteristics of !arious pumps and from information pro!ided in low ontrol, a Westin'house p

0alculator%40for%40+umps%40ip%40"heet.pdf

ction. he sa!in's !alues presented are calculated as follows$

ins is determined y multiplyin' the load profile % y the total annual hours of operation

percenta'e is taken from the fan load cur!es located on the an ur!es worksheet

determined y multiplyin' the full load pump power( cell 9 or 8) y the correspondin' full load power perceusa'e (kWh) is determined y multiplyin' the associated full load power y the total annual hours in that in

the annual ener'y usa'e of the e&istin' and proposed usa'e (cell +4: - cell "4:)

umented source)

rmined from "tep #, or the user may input full load kW ased on field measurements$

rformance cur!e will e used in the calculations. ll part load cur!es were taken from the *onne!ille +ower d

operatin' characteristics of !arious pumps and from information pro!ided in low ontrol, a Westin'house

ction. he sa!in's !alues presented are calculated as follows$

ins is determined y multiplyin' the load profile % y the total annual hours of operation

e used in con;unction with site specific spot measurements and lo''ed data of

n' used to replace a throttlin' !al!e (e.'., triple-duty !al!e)

aken enter the !alue in cell 8

lale, estimate full load kW usin' calculation method in cells =1$=1 and standard power factor tale. Enter e

ecific scedules select custom or metered in cell *4/. Enter annual load profile in cells D4?$D:?

cell *4/ which represents the e&pected annual load profile



ecific scedules select custom or metered in cell *4/. Enter annual load profile in cells D4?$D:?

cell *4/ which est represents the e&pected annual load profile the pump will ser!e



percenta'e is taken from the fan load cur!es located on the an ur!es worksheet

determined y multiplyin' the full load pump power( cell 9 or 8) y the correspondin' full load power perce

usa'e (kWh) is determined y multiplyin' the associated full load power y the total annual hours in that in

the annual ener'y usa'e of the e&istin' and proposed usa'e (cell +4: - cell "4:)

umented source)

d from "tep #, or the user may input motor power ased on field measurements$

ad factor in cell 1

osition in cell E44 and enter the !al!e percent open position in cell 41

a!in's !alues presented are calculated as follows$

e, or calculated ased on the percent load reduction caused y usin' a throttlin' de!iseumps power is reduced (known as ridin' the pump cur!e)

l 41 if >now E&istin' apacity is selected or calculated from a standard throttle position cur!e contained on t

on cur!e from +ump ur!es worksheet and the system % flow

from +ump ur!es worksheet and the system % flow

of the e&istin' and proposed usa'e (cell +#4 - cell "#4)



surements select >nown E&istin' apacity in cell E44 and enter the flow as a percenta'e of the full load @



ministration pulished documents

ulication, *ulletin *-8/#, 812e!-3" 8#4#.

ta'e

ministration pulished documents

ulication, *ulletin *-8/#, 812e!-3" 8#4#.

stimated kW calculated in cell *=1 into cell 8




ta'e

he hrottlin' !al!e cur!es worksheet if >now !al!e position is selected


3 in cell 41



Fan Motor Information

#0.00 p

?#.00% percent

80.00%

alculated full load power$ 1./1 $'

overrides calculated pow

(perating Parameters

=,000 rs)yr

Fan Control Metod Selection

onstant 5olume

5"D

"oad Curve Selection

Look up table reference #

A5 fan 4

A5 fan Bser <nput

% flow

nalysis +rofile

0% 0% 0% 0%

#0% 0% 0% 0%40% 0% 0% 0%

:0% 0% 0% 0%

=0% 0% 10% 0%

/0% #0% 15% #0%

10% 40% 15% 40%

90% :0% 20% :0%

80% 40% 15% 40%

?0% #/% 15% #/%

#00% /% 10% /%

!otal *++% *++%

Enter nameplate horsepower$

Enter nameplate efficiency$

Enter motor load factor$ percent default !0%"

r, Enter motor power, if measured$ $'

Enter hours per year fan operates$

Select e&istin' control type$

Select proposed control type$

Select load cur!e profile

% time atapacity

% time atapacity



nnual ener'y sa!in's, kWh #:,081

+ercent sa!in's =?.8%

ECA of proposed system #,??=

r - leave blank if unknown

Part load performance E&is

% flo# re,d (p rs Full load po#er

0% 0 #00%

10% 0 100%

40% 0 #00%

Look up table reference # 30% 0 100%? =0% 0 #00%

50% 400 100%4 10% 800 #00%

70% 1,200 100%80% 800 #00%

90% 600 100%#00% 400 #00%

!otal ./+++

0% 10% 200%

5%

10%

15%

20%

25%

30%

35%

%

% Time at Capacity



Savings Analysis Results

ing system Proposed system Savings

$' $' Full load po#er $' $' $'

1./1 0 /% 0.:# 0 0

6.56 0 5% 0.31 0 0

1./1 0 /% 0.:/ 0 0

6.56 0 8% 0.53 0 0

1./1 0 #:% 0.8/ 0 0

6.56 2,626 20% 1.33 532 2,094

1./1 /,4/4 :0% #.?? #,/?/ :,1/1

6.56 7,877 43% 2.85 3,423 4,4541./1 /,4/4 10% :.?4 :,#:8 4,##=

6.56 3,939 80% 5.22 3,131 8071./1 #,:#: #0:% 1.91 #,:/# -:8

01/023 *4/*5* *4/+31

30% 40% 50% 60% 70% 80% 90% 100%

Load Profle

Flow (percent o ull ow required to meet load)



Pump Motor Information

#00.00 p

?/.0% percent

80.0%

alculated full load power$ 14.88 $'

10.00 overrides calculated pow


=,000 rs)yr

Pump Control Metod Selection

6one-onstant 5olume

5"D

"oad Curve Selection


ustom or 3etered 1

ustom or 3etered Bser <nput

% flow

nalysis +rofile

0% 0% 0% 0%

#0% 0% 0% 0%40% 0% 0% 0%

:0% 0% 0% 0%

=0% 0% 10% #0%

/0% 0% 15% #/%

10% 0% 15% #/%

90% 0% 20% 40%

80% 0% 15% #/%

?0% 0% 15% #/%

#00% 0% 10% #0%

!otal 0% 100%





Enter hours per year pump operates$



Select load cur!e profile

% time atCapacity

% time atCapacity





/

4




nnual ener'y sa!in's, kWh #44,:?:

+ercent sa!in's /#.0%

ECA of proposed system #,?=1

Part load performance E&isting system

% flo# re,d (p rs Full load po#er $' $'

0% 0 #00% 10.00 0

10% 0 100% 60.00 0

40% 0 #00% 10.00 0

30% 0 100% 60.00 0

=0% =00 #00% 10.00 4=,000

50% 600 100% 60.00 36,000

10% 100 #00% 10.00 :1,000

70% 800 100% 60.00 48,00080% 100 #00% 10.00 :1,000

90% 600 100% 60.00 36,000#00% =00 #00% 10.00 4=,000

!otal ./+++ 0.+/+++

0% 10% 20% 30% 40% 50%

5%

10%

15%

20%

25%

30%

35%

Load Profle

% Flow (percent o ull o

% Time at Capacity



Proposed system Savings

Full load po#er $' $' $'

49% #1.=9 0 0

19% 11.47 0 0

#=% 8./? 0 0

13% 7.83 0 0

#/% ?.#8 :,194 40,:48

21% 12.64 7,586 28,414

:0% #8.44 #0,?:4 4/,018

43% 25.91 20,730 27,27010% :/.94 4#,=:4 #=,/18

79% 47.64 28,585 7,415#0:% 1#.18 4=,19# -19#

**5/1+5 *00/464

0% 60% 70% 80% 90% 100%

required to meet load)



Pump Motor Information

#00.00 p

?/.0% percent

80.0%

alculated motor power$ 14.88 $'

overrides calculated pow


=,000 rs)yr

Pump Control Metod !election

hrottle 5al!e

5"D

"#i$tin Flow &etermination

>nown 5al!e +osition

/0.00 %

80.00 % % of f

Estimating po#er 7$'8 from measured amps9

kW amps !olts ph power factor

2:5. 8.0 =10 : 0.?0

Estimating po#er 7$'8 from rated full load amps9

kW C !olts ph power factor load factor

2:5. #0.0 =10 : 0.?0 0.80

Motor Efficiency ; Po#er Factor

Efficiency Po#er Factor

<P Std Prem: Std Prem:

0.00# /0.00% //.00% /0.00% //.00%

0.4/0 14.90% 19./0% /:.::% /9.80%

0.::0 11.00% 18.80% 14.=4% 1=.#1%

0./00 1?.00% 9:.?0% 1#.18% 1:.:/%

0.9/0 91.00% 98./0% 11.00% 9=.//%

#.0 84.0=% 8=./?% 94./0% 91./0%

#./ 8:.19% 8/.8:% 94.?0% 99.40%

4.0 8:.9:% 8/.?8% 91.?0% 98.80%

:.0 81.#4% 88./=% 98.#0% 80.00%

/.0 81.8#% 88.=9% 84.40% 8:.40%

9./ 88.#1% ?0.08% 8:.#0% 8:.=0%

#0 8?.4/% ?0./8% 8=.00% 8/.40%

#/ ?0.04% ?#.:9% 8=.90% 8=.90%





Enter hours per year pump operates$



Select flow calculation method$

Enter e&istin' !al!e position (percent open)$

"nter e&istin' flow capacity$



40 ?0.#:% ?#.90% 81.00% 8/./0%

4/ ?#.9:% ?4./9% 8/.?0% 8/.80%

:0 ?#.//% ?4./9% 89.40% 81.=0%

=0 ?#.81% ?:.0=% 81.00% 8/.10%

/0 ?#.89% ?:.0#% 8/.10% 8/.?0%

10 ?4.80% ?:.=8% 89.:0% 8/.80%

9/ ?:.0#% ?:./0% 89.90% 81.80%

#00 ?:.#?% ?:.99% 89.80% 81.:0%#4/ ?:.#0% ?:.88% 88.10% 81.80%

#/0 ?:.=9% ?=.4=% 88.80% 81.?0%

400 ?:.1#% ?=.=0% 88.:0% 81.90%

:00 ?/.:0% ?/.80% ?0.=0% 81.80%

:/0 ?/.=0% ?/.?0% 8?.:0% 88.80%

=00 ?/.:0% ?/.10% 8?.=0% 81.?0%

=/0 ?/.00% ?/.00% ?0.00% ?0.00%

/00 ?/.40% ?/.40% ?0./0% ?0./0%

???? ?/.40% ?/.40% ?0./0% ?0./0%



nnual ener'y sa!in's (kWh) 11,?1#

+ercent sa!in's 49.8%


Part load performance E&is

System % Flo# (p rs Full load po#er

8/% =,000 ?1%

!otal ./+++


1

4


#

$stiated total flow

8/%

ll load GPM




ing system Proposed system Savings

$' $' Full load po#er $' $' $'

10.#: 4=0,/#? 1?% =:.:? #9:,//8 11,?1#

0.+/2*6 *54/223 11/61*



Fan System !ype Pump System !ypes

VSD 2 VSD

Eddy urrent Dri!es : Eddy urrent Dri!es

Inlet Guie Vane, !C !an" 4 #$&ue C$n'ete

<nlet @uide 5ane, *< irfoil ans / 6one-onstant 5olume

Inlet Dampe ($) 6 #*$ttle Val'eutlet Damper, ans 9

+utlet Dampe, (I -i$il !an" 8

onstant 5olume ?



Fan Curves 4-Duty Flo# Selection

2 /V-C an 2 n$n Val'e $"iti$n

: 3edium Coad : >nown E&istin' apacity

4 $ $a 4

/ @ara'e an /

6 Cu"t$m $ etee 6



Pump Curves

1 eium $a 3

4 Cow Coad =

Cu"t$m $ etee 6



% Design Pump Po#er 7$'8

2 3 4

% Capacity 7=PM8 VSD Eddy Current !or,ue Converter

0% 27.4 16.4 13.5

*+% #?.# #9.0 #8.4'0% 14.3 20.0 24.9

4+% #:.0 4/.0 ::.=

0% 15.3 32.0 43.1

2+% 4#.# =0.9 /:.9

0% 30.4 51.1 64.8

5+% =:.4 14.8 9/.8

*0% 59.5 75.7 86.5

6+% 9?.= 8?.1 ?1.:

100% 102.8 104.4 104.9

0% 20% 40% 60%0.0

20.0

40.0

60.0

80.0

100.0

120.0

) 19)2 : 63.7) : 55.2124

;< 1

) 176.2)2 100.853) : 27.44751

;< 1

Pump Control T

% Capacity (+PM)

% &e$in Pump Power (,-)



5 6

!rottle Valve

100.0 55.2

#00.0 1#.=100.0 67.2#00.0 94.1

100.0 77.7#00.0 84.:

100.0 86.6#00.0 ?0./

100.0 94.0#00.0 ?9.4

100.0 99.9

>one-ConstantVolume

80% 100% 120%

pe$

=y Cuent

VSD

$lyn$mial VSD

#$&ue C$n'ete

>$neC$n"tant V$lume

#*$ttle Val'e

$?ait*mic #*$ttle Val'e

$lyn$mial #*$ttle Val'e



% Design Fa

2 3 4 5

% Capacity 7CFM8 VSD Eddy Current

0% 4.8 10.4 20.0 47.3

*+% =.8 #9.0 40.1 /4.1

'0% 5.4 20.0 21.6 55.8

4+% 8.0 4/.0 4:.: /9.=

0% 12.9 32.0 26.4 58.5

2+% 40.: =0.9 :#./ /?.?

0% 30.4 51.1 38.9 62.3

5+% =:./ 14.8 =?.= 11.9

*0% 59.8 75.5 63.3 73.8

6+% 9?./ 8?.1 8#.= 8=.1

100% 102.9 104.4 104.0 99.8

Inlet =uide VaneControl For#ard

Curve Fans

Inlet =uide VaneControl/ ?I ; Airfoil

Fans

0% 20% 40% 60%0.0

20.0

40.0

60.0

80.0

100.0

120.0

Fan Con

% Capacity (C

% &e$in Fan Power (,-)



Po#er 7$'8

6 & ! '

Inlet Damper ?o& Constant Volume

50.3 20.4 55.9 100.0

/1.# 44.: /4.1 #00.0

59.8 25.6 53.3 100.0

14.4 :0.= /9.4 #00.0

64.0 36.7 63.6 100.0

11.0 ==./ 9#./ #00.0

69.1 53.8 80.2 100.0

9:.? 1=.1 88.9 #00.0

81.2 76.9 96.3 100.0

?#.? ?0.1 #04.# #00.0

106.7 105.9 105.2 100.0

(utlet Damper Control

For#ard Curve Fans

(utlet Damper Control/Radial ?lade ?ac$#ard

Inclined ; Airfoil Fans

80% 100% 120%

rol Type$

VSD

=y Cuent

Inlet Guie Vane C$nt$l !$a Cu'e

!an"

Inlet Guie Vane C$nt$l, (I -i$il !an"

Inlet Dampe ($)

+utlet Dampe C$nt$l !$a Cu'e !an"

+utlet Dampe C$nt$l, ;aial (lae

(ac@a Incline -i$il !an"

C$n"tant V$lume

FM)



2 3 4

% Capacity <VAC fan Medium "oad "o# "oad

+% 0% 0% /%

10% 0% 0% 10%

0+% 0% 0% #0%

.0% 0% 5% 10%.+% 0% #0% 40%

/0% 10% 20% 10%

1+% 40% :0% #0%

0% 30% 20% 10%

3+% 40% #0% #0%

0% 15% 5% 5%

*++% /% 0% 0%

*++% *++% *++%



5

C( =arage Sensor Custom or Metered

10% 0%

0% 0%

0% 0%

0% 0%0% 0%

20% 0%

#0% 0%

10% 0%

0% 0%

0% 0%

0% 0%

*++%



Typical 2al2e3damper perormance

% open

% flo#

!ypical valve

100 100

6+ ?8

*0 965+ ?:

0 90

2+ 8/

0 79

4+ 1?

'0 55

*+ :/

0 0

0 100

10

20

30

40

50

60

70

8090

100) 0.000002331)

;< 0.9995467579

Typical T

% Flow



- e"i?n p$int, $peatin? c$niti$n" it* t*$ttlin? 'al'e patially

( $peatin? c$niti$n", t*$ttlin? 'al'e 100% $pen

C $peatin? c$niti$n", pumpAan "pee euce



20 30 40 50 60 70 80 90 100

4 : 0.0006631702)3 0.0726223776)2 : 3.9524475524) : 0.5944055944

rottle 4al2e Performance Cur2e

% 5pen



l$"e