M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations T a b l e
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c o n t e n t s I Introduction.......................................................... 2 Saving energy....................................................... 2 - Controlling capacity to actual need .................... 3 - Examples ............................................................. 5 - Variable speed duty ............................................ 8 - Constant speed duty .......................................... 9 - Reducing maximum kW demand ....................... 9 - Removing unneccessary energy loss caused by vanes and valves ......................................... 10 Reduction in mechanical wear and tear ......... 10 Increasing comfort level.................................... 10 - Controlling comfort & reducing fan and pump noise .................................................................. 11 Calculation of pay back time............................ 12 Conclusion.......................................................... 13 I I I I I 2 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations I n t r o d u c t i o n C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: When using a VSD, accurate temperature and pres- sure control can be maintained. C alculation of pay back time: C alculation of pay back time: C alculation of pay back time: C alculation of pay back time: C alculation of pay back time: The energy savings will ensure a short pay back time of the investment in VSDs. Typically 1-2 years. Regarding Singapore (M arch 1996): Regarding Singapore (M arch 1996): Regarding Singapore (M arch 1996): Regarding Singapore (M arch 1996): Regarding Singapore (M arch 1996): The Singaporean government has introduced a writing off scheme for equipment used for energy saving purposes, via the taxes. This will make it even more attractive to invest in energy saving equipment. T TT TTypical advantageous applications: ypical advantageous applications: ypical advantageous applications: ypical advantageous applications: ypical advantageous applications: Experience shows that the payback time for the following applications is very short: VAV AHUs (fans and pumps) Secondary chilled water pumps Constant pressure ventilation fans Condenser fans Saving energy Save energy and reduce costs by: 1. Controlling the HVAC systems capacity to match the actual need. 2. Reducing maximum kW demand of the building. 3. Removing unnecessary energy loss caused by vanes and valves. I Introduction Saving energy: Saving energy: Saving energy: Saving energy: Saving energy: Energy savings can be obtained by reducing the speed of some of the most energy consuming instal- lations in buildings: pumps and fans, used in HVAC applications. Pumps and fans in old, existing HVAC installations, normally run at full speed all the time. Adjustment to actual flow or pressure demands is usually performed by valves, dampers or guide vanes. This is not energy efficient. When using a VSD to control the speed of a pump or fan, considerable energy savings can be gained. Reduction of mechanical wear and tear: Reduction of mechanical wear and tear: Reduction of mechanical wear and tear: Reduction of mechanical wear and tear: Reduction of mechanical wear and tear: Besides the energy savings, fitting VSDs on fans and pumps will reduce the wear of belts, bearings and valves, reducing the overall maintenance costs. Increasing comfort level: Increasing comfort level: Increasing comfort level: Increasing comfort level: Increasing comfort level: By reducing the speed of a centrifugal fan or pump, the acoustic noise level as well as the draught from fan systems are reduced. Water hammer from pump systems can be totally avoided. I 3 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations I Energy savings of up to 50% , or even more, is often possible in a typical installation, but only by using a VSD. Fig. 1, on this page, shows the typical power con- sumption of valve control and VSD control. Energy savings according to the actual need, will of course depend on the variations in need. O n very warm days, aircon and ventilation systems will have to run at full speed, but this will only happen a few days over the year or a few hours a day. The rest of the year or during off-peak periods every day, energy will be saved. Variable air systems using constant speed fans with dampers or guide vanes controlling the airflow, consume a lot of energy by constantly running the motor at full speed. Pumping circuits, e.g. chillers, running at constant speed waste chilled water by using by-pass loops, returning the excess chilled water not used by the in- stallation. Energy is wasted both in pump motors and in unnecessarily cooled water. In comparison to power consumption in constant speed systems, power consumption in variable speed systems using VSD, can be calculated according to the actual need (P = n 3 ): E n e r g y
s a v i n g Valve control Controlling capacity to actual need Centrifugal pumps and fans run according to a Varia- ble Torque characteristic. Changing the speed of a pump or fan will change the torque demand by the square of the speed (n): T = f (n 2 ). By changing the speed to 80% of the nominal value, the torque demand will thus only be about 64% of the nominal value. The power consumption, however, of a pump or fan motor is according to a cube law, P = f (n 3 ). This means that by reducing the speed to 80% of the maximum value, the power consumption will be reduced to about 50% of nominal value. E.g.: At 80% speed the power consumption is = 0. 8 3 = 0. 512 = 51. 2% Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1 Area of saved energy 100 % 52 % Valve control % Power % Power 80% 100% 4 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations E n e r g y
s a v i n g How many hours at a speed (i. e. flow requirement) of: 100% = Power consumed 100% 90% = 72.9% 80% = 51.2% 70% = 34.3% 60% = 21.6% 50% = 12.5% M ultiplying the number of hours (h) running at the various speeds by the associated amount of power (kW), and adding the values, will show the total energy consumption (kWh) per year for the actual mo- tor driven by a VSD. Fig. 2, below, shows a typical capacity characteristic of a pump as well as the associated motor shaft out- put in kW. Practical figures may vary with different pump designs. Fig. 2 Fig. 2 Fig. 2 Fig. 2 Fig. 2 Pump characteristics: Compared to constant speed operation, the diffe- rence from the above mentioned variable speed calculations, represents the savings in energy. By repeating this calculation for other pump and fan systems, within a building, the total energy saving of the whole building can be calculated. Two theoretical examples based on general experience as well as one practical example, all showing the necessary calculations, are given on the following pages. Valve regulation follows A 1 to B 1 curve. By speed regulation it is possible to utilize the pumps characteristic. Thereby power consumption follows the dotted curve from A 1 to C 1 . Fig. 2, below, shows a typical capacity characteristic of a pump as well as the associated motor shaft out- put in kW. Practical figures may vary with different pump designs. 5 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations a) a) a) a) a) Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy consumption per week: 15 kW x 66h = 990 kWh Electricity rate is US$ 0. 10 / kWh. Energy cost per year: 990 kWh x US$ 0. 10 x 52 = US$ 5, 148 b) b) b) b) b) Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Assume average speed is 75% corresponding to 42% power consumption. Energy consumption per week: 42% of 15 kW x 66h = 416 kWh Energy cost per year: 416 kWh x US$ 0. 10 x 52 = US$ 2, 163 c) c) c) c) c) Value of energy saved by using variable speed: Value of energy saved by using variable speed: Value of energy saved by using variable speed: Value of energy saved by using variable speed: Value of energy saved by using variable speed: US$ 5, 148 - US$ 2, 163 = US$ 2, 985 e) e) e) e) e) Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): VSD price : Transmitter for closed loop operation (e. g. 1 pressure transmitter) : US$ 300 Labour hours for mounting of drive and transmitter ( 4 h) : US$ 200 Installation of drive and transmitter (20 m of ctrl. cable) and test run of application : US$ 100 Total installation cost : US$ 4, 300 E n e r g y
s a v i n g (Calculations on pay back time for all three examples will be shown at the end of part 1). Example 1 A 15 kW AHU operating for 12 hours during week days and 6 hours during week-end. In total 66 hours per week In total 66 hours per week In total 66 hours per week In total 66 hours per week In total 66 hours per week. I US$ 3, 700 Note: Note: Note: Note: Note: All calculations are shown in US$, as a neutral currency. When you convert the figures to your currency, you will see that the energy savings and pay-back time are just as favourable. 6 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations E n e r g y
s a v i n g Example 2 A 15 kW AHU operating for 24 hours during week days and week-ends. In total 24h x 365 days = 8760 hours per year In total 24h x 365 days = 8760 hours per year In total 24h x 365 days = 8760 hours per year In total 24h x 365 days = 8760 hours per year In total 24h x 365 days = 8760 hours per year. .. .. a) a) a) a) a) Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy consumption per year: 15 kW x 8760h = 131, 400 kWh I Electricity rate is US$ 0. 10 / kWh. Energy cost per year: 131, 400 kWh x US$ 0. 10 = US$ 13, 140 b) b) b) b) b) Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Assume average speed is 80% corresponding to 51. 2% power consumption. Energy consumption per week: 51. 2% of 15 kW x 8760h = 67, 276 kWh Energy cost per year: 67, 276 kWh x US$ 0. 10 = US$ 6, 728 c) c) c) c) c) Energy cost saved by using variable speed: Energy cost saved by using variable speed: Energy cost saved by using variable speed: Energy cost saved by using variable speed: Energy cost saved by using variable speed: US$ 13, 140 - US$ 6, 728 = US$ 6, 412 e) e) e) e) e) Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): VSD price : US$ 3, 700 Transmitter for closed loop operation (e. g. 1 pressure transmitter) : US$ 300 Labour hours for mounting of drive and transmitter ( 4 h) : US$ 200 Installation of drive and transmitter (20 m of ctrl. cable) and test run of application : US$ 100 Total installation cost : US$ 4, 300 7 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations E n e r g y
s a v i n g Example 3 Shows the design calculations for the Asian M useum of History, Hong K ong. G iven is the buildings cooling load curve for a period of 24 hours: I Fig. 3 Fig. 3 Fig. 3 Fig. 3 Fig. 3 Fig. 4 Fig. 4 Fig. 4 Fig. 4 Fig. 4 Based on fig. 3, a block cooling load profile was made, giving some expected average fan speed requirement values in % , using VSDs, to meet the cooling load: % is expected fan speed to meet cooling load 8 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations E n e r g y
s a v i n g From G ood Practice G uide book no. 2 issued by the UK Department of Energy, graphs were used to convert the fan speeds [% ], found in fig. 4, to power consumption [% ]. Fig. 5 Fig. 5 Fig. 5 Fig. 5 Fig. 5 Fig. 6 Fig. 6 Fig. 6 Fig. 6 Fig. 6 Variable Speed Duty Based on avg. fan speeds as noted in fig. 4 and the power consumption (kW) relating from fig. 5, the energy consumption in the different periods, as well as the total energy consumption (kWh), for Variable Speed Duty can be calculated: I Period Av. Fan Speed % Power Actual Hours kWhs In period % Power kW R un Used 1 12 5 2 8 16 2 50 18 6 3 18 3 80 50 17 3 51 4 90 70 23 2 46 5 78 48 16 3 48 6 35 10 4 5 20 Per day 24 199 1. VSD 2. G uide vane 3. Damper 4. Hydraulic/Eddy current coupling 9 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations E n e r g y
s a v i n g For the alternative, Constant Speed Duty, calculations of the energy consumption were also made: Constant Speed Duty (Average values): Assume 50% of fan load (16 kW) for 24h = 384 kWh (O ne group of fans constantly running) Assume 50% of fan load (16 kW) for 12h = 192 kWh (O ne group of fans running day time only) Energy consumed per day: 576 kWh Now the energy savings energy savings energy savings energy savings energy savings from running V VV VVariable Speed Duty ariable Speed Duty ariable Speed Duty ariable Speed Duty ariable Speed Duty, as opposed to Constant fan Speed Duty Constant fan Speed Duty Constant fan Speed Duty Constant fan Speed Duty Constant fan Speed Duty, can be calculated: Based on running 365 days / year: Constant Speed Duty 365 x 576 kWh = 210, 240 kWh Variable Speed Duty 365 x 199 kWh = 72, 625 kWh Saving = 137, 615 kWh Savings in energy costs per year: 137, 615 kWh at US$ 0. 1 / kWh = US$ 13, 762 US$ 13, 762 US$ 13, 762 US$ 13, 762 US$ 13, 762 This saving represents a 65% reduction of the energy bill ! This saving represents a 65% reduction of the energy bill ! This saving represents a 65% reduction of the energy bill ! This saving represents a 65% reduction of the energy bill ! This saving represents a 65% reduction of the energy bill ! Total cost of Danfoss VLT
6000 HVAC drives in this case were = US$ 17, 406
Reducing maximum kW demand When using dedicated types of Variable Speed Drives, the high starting current of the motors will be avoided, as these drives include soft starting feature whereby zero starting current is produced, apart from the magnetising current. Thereby the maximum demand current is reduced. This adds to the energy savings already obtained with the pumps and fans. Fig. 7, on this page, shows the differences in starting current for various types of drive systems. In Singapore M aximum Demand is today charged on the highest continuous power consumption, lasting at least half an hour, over a period of one month. In a retrofit situation existing starters (f.ex Y/-starters) and power factor correction equipment (PFC capacitors) can be removed reducing energy-loss and maintenance relating to these components. I Fig. 7 Fig. 7 Fig. 7 Fig. 7 Fig. 7 I 1 = VLT 6000 HVAC 2 = Star-Delta 3 = Soft Starter 4 = Direct-on-line 10 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations E n e r g y
s a v i n g I Removing unnecessary energy loss caused by vanes and valves Dampers, guide vanes and valves in fan or pump sy- stems cause a pressure drop across them dependent on the speed of the air- or water flow passing through. When retrofitting with VSDs dampers, guide vanes or valves can just be left fully open, or simply removed . Using a VSD, reduces or even eliminates the unnecessary pressure drops and thereby the unnecessary power consumption caused. This improves overall efficiency and capacity. I Reduction in mechanical wear and tear When a HVAC installation no longer runs at full speed, additional benefits are provided: Besides the energy savings, fitting VSD on fans: Besides the energy savings, fitting VSD on fans: Besides the energy savings, fitting VSD on fans: Besides the energy savings, fitting VSD on fans: Besides the energy savings, fitting VSD on fans: Increases lifetime of belt drives on fans Less wear on bearings, as the shock load on belt and bearings is removed through soft start/stop. M odern VSDs include belt monitoring, meaning longer intervals between maintenance. and because vanes, dampers and actuators are no and because vanes, dampers and actuators are no and because vanes, dampers and actuators are no and because vanes, dampers and actuators are no and because vanes, dampers and actuators are no longer needed: longer needed: longer needed: longer needed: longer needed: No more jammed guide vanes / dampers No more loss of performance No guide vane maintenance costs Lower noise levels / better air quality control Longer intervals between air filter changing (lower speed = less dirt) O n pumps, fitting VSD will: O n pumps, fitting VSD will: O n pumps, fitting VSD will: O n pumps, fitting VSD will: O n pumps, fitting VSD will: Remove water hammer ( at start/stop situations) Prevent blown valves Reduce leakages as pressure is kept constant As it appears from the above, several nuisance pro- blems can be avoided and considerable savings can be gained. Increasing comfort level Noise from fans: As a by-product of the energy saving from reducing fan speeds, acoustic air movement noise from the fan is reduced. Noise from fans in a quiet environment can be very annoying. If a fan, sized for full occupancy, for example, is supplying a partly occupied room, the acoustic noise level can be as high as e. g. 70 dBA. The noise level will vary dependent on the throttling with dampers or guide vanes. The more throttling the more noise. K eeping dampers or guide vanes fully open and reducing the speed from 100% to f. ex. 50% , reduces the noise by 16. 5 dBA. (A reduction of 10 dBA corresponds to a 50% reduction of the noise level), according to standard fan catalogues. The following formula shows how to calculate the above. Calculating noise reduction: 55 x Log (dBA) New speed O ld speed I In constant speed pump systems bypass loops are commonly used as part of the regulating function, keeping constant pressure at varying flow. Bypass sy- stems for pumps can be equally eliminated by using a VSD to control the flow of the pump according to the actual need. 11 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations C o m f o r t
i n c r e a s e The relationship is explained as follows: Fig. 8 Fig. 8 Fig. 8 Fig. 8 Fig. 8 Sound level on air quantity regulation Noise is a determining factor in for example central Airconditioning for hotels, hospitals etc. Draught: Draught: Draught: Draught: Draught: By reducing the speed of a centrifugal fan or pump, the acoustic noise level as well as the draught from fan sy- stems, can be very much reduced too. That increases comfort and may reduce sickness leave. Leaks: Leaks: Leaks: Leaks: Leaks: Leaking water from pump systems, usually caused by water hammer, can be totally avoided by using a VSD with zero starting surge and a ramp to allow an exten- ded starting period. This also extends quality and life time on pipework and fittings. C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: When using a VSD, accurate temperature and pres- sure control can be maintained. See Fig. 9. Fig. 9 Fig. 9 Fig. 9 Fig. 9 Fig. 9 12 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations S a v i n g s I Calculation of pay back time When considering energy savings it is important to know the investments necessary to obtain the expected energy savings. And most interesting of all, maybe, to know about the pay back time of the investment. Calculation of the pay back time is initially done for each VSD installed and eventually the data for other frequency converters are added. First of all the investment necessary for obtaining energy savings has to be calculated: - The price of the frequency converter together with necessary transmitters. - The cost of installing the frequency converter incl. wiring of power and control signal as well as the necessary changes in pipe- and/or duct work. Secondly: - The energy savings, calculated as the difference between the energy consumption in a constant speed system compared to a frequency converter controlled system, based on the examples described on pages 7, 8 and 9, multiplied by the electricity rate per kWh, has to be established. Thirdly: - The savings on maintenance, has to be added to establish the total savings. Eventually the pay back time can be calculated as the total cost of having a VSD installed, divided by the total savings (energy and maintenance) for one year: Pay back time (simple): Total cost of installing VSD Total energy savings for one year Pay back time (real): Total cost of installing VSD (Total energy sav. pr. year + savings on maintenance/spare parts) I Example 2: Pay back time Pay back time Pay back time Pay back time Pay back time based on theoretical example 2: Total installation cost of VSD = Energy saving per year US$ 4, 300 = 0. 67 years 0. 67 years 0. 67 years 0. 67 years 0. 67 years US$ 6, 412 I I Note: Note: Note: Note: Note: Savings on maintenance has not been added in this example, as it depends on the actual si- tuation, but the formula indicates that the pay back time will be even shorter, than estimated here. Note: Note: Note: Note: Note: Savings on maintenance has not been added in this example, as it depends on the actual si- tuation, but the formula indicates that the pay back time will be even shorter, than estimated here. Example 3: Pay back time based on practical example 3: Total cost of VSD = Energy saving per year US$ 17, 406 = 1. 26 years 1. 26 years 1. 26 years 1. 26 years 1. 26 years US$ 13, 762 Note: Note: Note: Note: Note: Savings on maintenance has not been added in this example, as it depends on the actual si- tuation, but the formula indicates that the pay back time will be even shorter, than estimated here. Example 1: Pay back time Pay back time Pay back time Pay back time Pay back time based on theoretical example 1: Total installation cost of VSD = Energy saving per year US$ 4, 300 = 1. 44 years 1. 44 years 1. 44 years 1. 44 years 1. 44 years US$ 2, 985 13 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations S a v i n g s Conclusion As described in the various sections of this paper, the majority of existing HVAC installations, which are running with constant speed pumps and fans, can be converted into profitable, cost efficient, energy saving (money saving) installations, by investing in Variable Speed Drives and a few transmitters. Furthermore, the cost reduction for maintenance and replaceable parts is obvious and the improved comfort level will enhance the indoor climate and eventually increase the human work output. I All together, a huge reduction of the energy bill, often 50% or more, a very short pay back time of the investment, typically 1 or 2 years and increased comfort level are obtained. Typical applications where substantial energy savings can be achieved by using VSD: G Supply fans G Return fans G Exhaust fans G Smoke extract fans G Condenser fans G Induced draft boiler fans G Cooling tower fans G Condenser pumps G Chilled water pumps G Hot water/domestic water pumps G District heating supply pumps G District cooling pumps G Pressure booster pumps Simple retrofit with VSD is possible with modern dedicated HVAC drives including basic and vital HVAC components. The booklet, HO W HO W HO W HO W HO W to use VSD in Existing HVAC Instal- lations M A. 35. J1. 02, Retrofit G uideline Part II, will explain in details how a VSD is installed in the easiest possible way. The HO W booklet will also describe how unnecessary problems can be avoided. I Next step 14 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations F o r
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n o t e s / c a l c u l a t i o n s 16 M C. 60. D1. 02 - VLT is a registered Danfoss trademark Why use VSD in existing HVAC installations F o r