and Outlet Dampers

VFD
VFD CALCULATORS
CALCULATORS
for
for Fan
Fan &
& Pump
PumpApplications
Applications
1-800-962-3787

Special thanks to the Bonneville Power Adminstration for permitting us to distribute this tool to energy professionals worldwide,
as well as Christopher B. Milan, PE, CEM Mechanical & Civil Engineer, B.P.A. for developing these calculators.

See the complete line of energy saving drives from Cerus by clicking on the photo below:

If you have any questions regarding these tools, please click to email Chris Milan at bpa.gov
This, and other handy calculators can be found at http://www.cerusind.com/calculators.asp
Click here for extensive analysis tools at DOE web site
 Comparison of Inlet and Outlet Dampers

Page 2 of 16 Bonneville Power Administration Revision No. 1

 Comparison of Inlet and Outlet Dampers

Page 3 of 16 Bonneville Power Administration Revision No. 1

 Fan Drives Power Graphs
Eddy Current Drive Fan Flow Control Adjustable Speed Drive Fan Flow Control
120.0 120.00
d Outlet Dampers

104.4 102.93
100.0 100.00

% of Design Input Power (kW)

% of Design Input Power (kW)

89.6

80.0 80.00 79.50

75.7

62.8
60.0 60.00 59.75

51.1

43.46
40.0 40.7 40.00
32.0
30.38
25.0
20.0 20.0 20.00 20.27
16.4 17.0
12.89
8.00
4.75 5.37
0.0 0.00
0 20 40 60 80 100 120 0 20 40 60 80 100 120
% of Design CFM % of Design CFM or % of Full Speed RPM

The power curves above are used in the energy savings analysis. Curves developed from data obtained by measuring the operating characteristics of
various fan systems and from information provided in "Flow Control", a Westinghouse publication, Bulletin B-851, F/86/Rev-CMS 8121. Curves are
representative, not precise,
final economic analysis should be based on actual power (kW) measurements of the fan system.

Page 4 of 16 Bonneville Power Administration Revision No. 1

 ADJUSTABLE SPEED DRIVE ENERGY SAVINGS CALCULATOR
~ Fan Applications ~
Fan Motor Information

Enter Nameplate Horsepower: 100.00 hp

Enter Nameplate Efficiency: 85.00 % www.cerusind.com
Enter Motor Load at Fan Design CFM: 80.00 % 1-800-3543787
Power(kW) at Fan Design CFM: 70.21 KW

Facility Information

Enter Hours per year fan operates: 80 hrs/yr

Enter Energy Charge: 0.05 $/kwh

Existing Flow Control Method and Fan Type

Select Flow Control and
Fan Type Below Click to go to the Fan Types worksheet for more information
1 Inlet Guide Vane, FC Fans 4 Outlet Damper, FC Fa 7 Selection 7 allows
Measured Power (kW)
1 2 Inlet Guide Vane, BI & Airfoil Fans 5 Outlet Damper, BI & Airfoil Fans readings to be used in
3 Inlet Damper Box 6 Eddy Current Drives the analysis

Duty Cycle Power Analysis Savings Analysis

Existing System ASD System

Enter
Percent of
Enter Percent of Design Existing Percent of Annual Energy Annual Energy Cost
Time at Do Not
Capacity (CFM) System Percent Existing System Design (kW) ASD System Power Savings (Kwh/yr) Savings ($/yr)
this Enter Data
Capacity of Design Power (kW) for ASD (kW)
(KW) Below System

0.0% 5.0% 20.00 14.04 5.90 4.14 39.60 $ 1.98

10.0% 5.0% 20.64 14.49 4.75 3.33 44.64 $ 2.23
20.0% 10.0% 21.57 15.14 5.37 3.77 90.99 $ 4.55
30.0% 10.0% 23.32 16.37 8.00 5.62 86.03 $ 4.30
40.0% 10.0% 26.44 18.56 12.89 9.05 76.09 $ 3.80
50.0% 10.0% 31.45 22.08 20.27 14.23 62.84 $ 3.14
60.0% 10.0% 38.92 27.32 30.38 21.33 47.97 $ 2.40
70.0% 10.0% 49.36 34.66 43.46 30.51 33.18 $ 1.66
80.0% 10.0% 63.33 44.47 59.75 41.95 20.13 $ 1.01
90.0% 10.0% 81.37 57.13 79.50 55.82 10.52 $ 0.53
100.0% 10.0% 104.01 73.03 102.93 72.27 6.04 $ 0.30
Totals: 100.0% 2,584.31 Kwh/yrexisting 2,066.29 Kwh/yrasd 518.03 $ 25.90

Sample Duty Cycles (these can be used as a guide if the duty cycle is not known)
Sample Duty Cycle - HIGH FAN LOADING Sample Duty Cycle - LOW FAN LOADING

70 60
55
Percent of Time at this Capacity

60
60
50
Percent of Time at this Capacity

50
40
40
30
25
30
20 20 20
20 15

10
10
5

0 0
50 75 Capacity (cfm) 90 30 50Design Capacity
Percent of 70 (cfm) 90
Percent of Design

Summary

Energy Savings: 518.03 KWH/yr Enter Labor Cost:

Cost Savings: $ 25.90 Total Cost: $ -
Enter Materials Cost: $ - Simple Payback: years

This calculator was developed by Chris Milan at the Bonneville Power Administration (BPA) and is intended to be used as an estimation of potential energy savings and simple payback for
ASD installations. Final economic decisions should be based upon more extensive analysis tools than what is provided here.

If you have any questions or comments, please email Chris Milan at the following: cbmilan@bpa.gov
More extensive analysis tools are available at the following DOE web site: http://www.eere.energy.gov/industry
* This is an Excel 2000 file and is approximately 2.5 MB in size.

Page 5 of 16 Bonneville Power Administration Revision No. 1


(FC) Forward-Curved Fans
ampers
The fan blades curve in the direction of rotation.
Descriptions and Fan Efficiencies
These fans are typically not as large as other fan
types and structurally are not very rugged. Fan
efficiencies are in the range of 55 to 65%.
The typical performance curve for a Forward
Curved fan contains a dip in the static pressure
Performance Characteristics
curve to the left of the point of maximum static
pressure. This region of the performance curve
indicates that the characteristics of the air flow
through the fan was not consistent. As the flow
increases, the static pressure increases and
decreases within this region. It is not
recommended to operate the fan within this
unstable region of the fan curve due to the
unpredictable flow characteristics. This area is
sometimes referred to as the "stall" region.
Due to the narrow openings between fan blades,
these fans are not suited for airstreams
containing particulate. These fans usually
operate at low volumes and low speeds such as
in residential HVAC units.
Applications
Page 6 of 16
Common Fan Types
(BI) Backward-Inclined Fans
The fan blades tilt back, away from the direction
of rotation. The main difference between fans in
this category is the shape and construction of
the blades. The Backward-Inclined Flat blades
tend to be more rugged and allow some
particulate to pass through but these blades are
not very aerodynamic and therefore are the least
efficient. The Backward-Inclined Curved blades
are more efficient but their orientation with the
air stream can allow moisture and particulate to
collect on the blades which reduces fan
performance and may cause excessive
vibrations. The efficiency ranges from 75 to
85%. The Backward-Inclined Airfoil blade
resembles the wing of an aircraft and is the most
efficient fan type with efficiencies over 90%.
The fan performance curve for Backward
Inclined fans is similar to the forward curve but
typically has a smaller dip in the static pressure
curve. The major difference of the backward
inclined fans is the characteristics of the BHP
curve. The horsepower curve does not increase
to a maximum amount at maximum flow rate but
instead will reach a peak and then drop off as
the flow rate continues to increase to it's
maximum amount. This characteristic allows the
designer to select a motor size for the worst
case(design) conditions and if any errors or
changes occur that would increase the flow
requirements, the fan will not be overloaded.
This is typically referred to as a "non-
overloading" power curve.
As stated above, these fans are typically "non-
overloading" and this characteristic makes them
a popular choice for applications were the
system performance is uncertain at maximum
flow rates. The inside of these blades are
usually hollow to reduce their weight but the
build up of moisture and particulate can lead to
cavities which reduces their efficiency. The
narrow openings can limit the size of particulate
in the air stream they can tolerate. These fans
are a good choice for installations on the clean
side of the process air stream for material and
dust handling systems and for forced-draft fans
in boilers. Bonneville Power
Radial-Blade Fans
These fans are typically the most rugged of all
types and can range from Paddle-Wheel design
to Flat Blades with corrosion resistance coatings.
These fans usually operate at lower volumes but
higher pressures than other fan types. The wide
openings between the blades allow larger
material to pass through and also minimizes
vibrations when operating during conditions
when the flow and pressure drops. The
construction of these fans allows them to be
modified to meet specific applications and to be
repaired at minimum costs. Typical ranges of fan
efficiencies for Flat Blades is 55 to 65% and 60
to 75% for the Radial Tip.
The performance curve for fans with Radial
Blade wheels is typically a smooth curve showing
the pressure steadily dropping from a maximum
at zero flow to a minimum pressure at full flow.
This characteristic allows stable operation of the
fan throughout a wide range of flow(cfm) by
adjusting the pressure. The corresponding BHP
curve increases at a linear rate as the fan flow
rate increases. The Radial Tip fan performance
curve is a blend of the Backward- Inclined and
Radial Blade curves. The BHP curve increases
to a maximum amount at maximum flow. The
Radial Tip is more efficient than the Radial Blade
and therefore requires less horsepower to
produce the same output.
These fans are the fans of choice for moving
material or air in harsh operating environments.
They are used to convey everything from air
filled with particulate to wood chips, rock or metal
scrap
Administration
Axial Fans
This fan group includes Propeller, Tubeaxial, and
Vaneaxial fans. The fan blades are installed
perpendicular to the air stream. The majority of
these fans can be operated in reverse which
allow them to supply or exhaust the air.
Propeller fans generate high airflows but
minimum pressure and are the least expensive
and least efficient. To increase the pressure and
efficiency these fans are placed inside a hollow
tube to form the Tubeaxial fan. To further
increase the efficiency and develop a more
unified air stream, outlet vanes are installed to
form the Vaneaxial fan.
The fan performance curve for this group of fans
indicates that they are capable of providing high
flow rates at lower pressures than other fan
types. These fans will typically have a unique
BHP curve that requires maximum power at zero
flow rate. The horsepower and static pressure
will increase and decrease as flow increases
until finally reaching a minimum value at
maximum flow rate. These variations in flow and
pressure result in different flow rates at the same
operating pressure, causing instability and
control problems. Operating within this region
should be avoided.
Propeller fans are common on cooling towers
and inexpensive exhaust systems. Tubeaxial
and Vaneaxial fans are used in HVAC exhaust
applications were higher pressures and flow
rates are required. All of these fans produce
significant airflow noise when compared to other
fans.
Revision No. 1
 operate at low volumes and low speeds such as
in residential HVAC units.
Applications
(FC) Forward-Curved Fans
Reference: "Improving Fan System Performance" Industrial Technologies and Best Practices Web Site at: http://www.oit.doe.gov
Page 7 of 16
system performance is uncertain at maximum filled with particulate to wood chips, rock or metal applications were higher pressures and flow
flow rates. The inside of these blades are scrap rates are required. All of these fans produce
usually hollow to reduce their weight but the significant airflow noise when compared to other
Common can lead toFan Types
build up of moisture and particulate fans.
cavities which reduces their efficiency. The
narrow openings can limit the size of particulate
in the(BI)
air stream they can tolerate. These
Backward-Inclined Fansfans Radial-Blade Fans Axial Fans
are a good choice for installations on the clean
side of the process air stream for material and
dust handling systems and for forced-draft fans
in boilers.
Bonneville Power Administration Revision No. 1
 % of Design Input Power (kW )
Inlet Vane Graphs
power curve is over loading….go 105%
Inlet Guide Vane Control, BI & Airfoil Fans
120.0
and Outlet Dampers Inlet Guide Vane Control, Forward Curve Fans
120.0

104.0

100.0 6 100.0 99.8

80.0 81.4

84.6

% of Design Input Power (kW)

80.0
63.3
60.0 73.8
49.4
66.7
40.0 62.3
38.9
60.0 57.4 58.5 59.9
31.5 55.8
23.3
26.4 52.6
20.0 20.0 20.6 21.6
47.3

40.0
0.0
0 20 40 60 80 100 120
% of Design CFM

20.0
Inlet Damper Box, General Curve
120.0
0.0
106.7 0 20 40 60 CFM
% of Design 80 100 120
100.0
91.9
% of Design Input Power (kW)

80.0 81.2

73.9

64.0
66.0
69.1 These power curves are used in the energy savings
60.0 56.1
59.8
62.2
analysis. Curves developed from data obtained by
50.3 measuring the operating characteristics of various
fan systems and from information provided in "Flow
40.0
Control", a Westinghouse publication, Bulletin B-851,
F/86/Rev-CMS 8121. Curves are representative, not
20.0 precise. Final economic analysis should be based on
actual power(kW) measurements of the fan system.
0.0
0 20 40 60 80 100 120
% of Design CFM
Page 8 of 16 Bonneville Power Administration Revision No. 1
 Outlet Damper Graphs
Outlet Damper Control, Outlet Damper Control, Radial Blade,
Forward Curve Fans Backward Inclined & Airfoil Fans
120.0 120.0
d Outlet Dampers
110.0
105.9
105.2
102.1
100.0 100.0
96.3
90.6
90.0 88.7
% of Design Input Power (kW)

% of Design Input Power (kW)

80.0 80.0 80.2
76.9

71.5
70.0
64.6
63.6
60.0 60.0
57.2
53.8 53.3
52.6
50.0
44.5
40.0 40.0
36.7

30.4 30.0
25.6
22.3
20.0 20.4 20.0

10.0

0.0 0.0
0 20 40 60 80 100 120 0 20 40 60 80 100 120
% of Design CFM % of Design CFM

The power curves above are used in the energy savings analysis. Curves developed from data obtained by measuring the operating characteristics of various fan
systems and from information provided in "Flow Control", a Westinghouse publication, Bulletin B-851, F/86/Rev-CMS 8121. Curves are representative, not
precise, final economic analysis should be based on actual power(kW) measurements of the fan system.

Page 9 of 16 Bonneville Power Administration Revision No. 1

 ADJUSTABLE SPEED DRIVE ENERGY SAVINGS CALCULATOR
~ Fan Applications ~
Motor Information

Enter Nameplate Horsepower: 50.00 hp

Enter Nameplate Efficiency: 95.00 % This Sample Input Sheet is for
This purposes
viewing Sample Inputonly.Sheet is for
No values
Enter Motor Load at Fan Design CFM: 90.00 % viewing purposes only. No values
can be inputted or changed. It is
Power(KW) at Fan Design CFM: 35.34 KW can be inputted or changed. It is
included here to give the user an
included here to give the user
idea of what types of values can be an
idea of whatinto
entered types of values
either the Fancan be
Facility Information
entered into either the Fan
Calculator or Pump Calculator
Calculator or Pump Calculator
worksheets.
Enter Hours per year fan operates: 8760 hrs/yr worksheets.
Enter Energy Charge: 0.05 $/kwh

Flow Control Method and Fan Type

Select Flow Control and
Fan Type Below Click to go to the Fan Types worksheet for more information
1 Inlet Guide Vane, FC Fans 4 Outlet Damper, FC Fans
5 2 Inlet Guide Vane, BI & Airfoil Fans 5 Outlet Damper, BI & Airfoil Fans
3 Inlet Damper, General Curve 6 Eddy Current Drives 7 Measured kW

Duty Cycle Power Analysis Savings Analysis

Existing System ASD System

Enter
Percent of Enter Percent
Annual Energy Annual Energy Cost
Design of Time at Existing Percent of Savings (Kwh/Yr) Savings ($/yr)
Capacity this Capacity System Do Not Existing Design (KW)
(CFM) Percent of Enter Data System for ASD
Design (KW) Below Power (KW) System ASD System Power (KW)
25.0% 15.0% 54.90 19.40 6.42 2.27 22,511.26 $ 1,125.56
50.0% 55.0% 71.53 25.28 20.27 7.16 87,270.91 $ 4,363.55
70.0% 25.0% 88.71 31.35 43.46 15.36 35,022.55 $ 1,751.13
90.0% 5.0% 102.08 36.07 79.50 28.09 3,494.89 $ 174.74
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Totals: 100.0% 231,719.64 Kwh/yrexisting 83,420.05 Kwh/yrasd 148,299.60 $ 7,414.98

Sample Duty Cycles (use these as a guide if the duty cycle is not known)
Sample Duty Cycle - HIGH FAN LOADING Sample Duty Cycle - LOW FAN LOADING

70 60
55
60
60 50
Percent of Time at this Capacity
Percent of Time at this Capacity

50
40
40
30
25
30

20 20 20
20 15

10
10 5

0 0
50 Percent of Design
75Capacity (cfm) 90 30 50Design Capacity
Percent of 70 (cfm) 90

Summary

Energy Savings: (Note 1) 148,299.60 KWH/yr Enter Labor Cost: $ 100,000.00

Cost Savings: $ 7,414.98 Total Cost: $ 100,950.00
Enter Materials Cost: $ 950.00 Simple Payback: 13.61 years

This calculator was developed by Chris Milan at the Bonneville Power Administration (BPA) and is intended to be used as an indication of the potential energy savings and
simple payback for ASD installations. If you have any questions or suggestions for improvements, please contact Chris Milan at cbmilan@bpa.gov. More extensive analysis
tools are available at: http://www.eere.energy.gov/industry.

Page 10 of 16 Bonneville Power Administration [Revision No. 1]


Inlet Guide Vanes and
Inlet Dampers
Inlet Guide Vanes are installed across the opening of the fan inlet.
By opening and closing, they vary the amount of air entering the
fan and change the profile of the entering airstream. As the air
passes through the vanes it begins to swirl in the same rotation as
the fan impeller, this pre-spinning of the air reduces the
momentum that the fan blades can impact on the entering air and
therefore reduces the velocity and pressure of the discharged air.
As the vanes continue to close, this swirling action increases and
continues to decrease the pressure and flow the fan delivers to
the system. The fan horsepower is proportional to the flow and
pressure, therefore the horsepower requirement also decreases.
Because the inlet vane opening affects all three of these fan
characteristics, a new fan performance curve is created whenever
the vane position is changed. Inlet control does not affect the
Characteristics
system curve, as vane positions change the fan performance
curve rides up and down the system curve.
Operating
Inlet dampers can be oriented to provide the same affect as inlet
guide vanes but usually are not as effective at inducing the
appropriate swirl. The blades typically operate in parallel with
each other. If the inlet dampers are installed too far from the fan
inlet or are not oriented properly, they only serve to restrict the
entering airflow.
Inlet Dampers are usually a better choice of flow control than
Outlet Dampers because when properly installed, they allow the
fan horsepower to be reduced as the flow is reduced. Inlet Guide
Vanes usually provide more accurate control of fan performance
than Inlet Dampers. Inlet Guide Vanes are an efficient method
for controlling flow rates down to approximately 70% of capacity.
This would correspond to a vane position of approximately 50%
Disadvantages
Advantages/
closed. If the desired fan flow rate requires that the vanes be
closed more than 50%, adjustable speed drives usually provide
more efficient controllability by reducing the fan speed rather than
continuing to restrict the fan inlet with the guide vanes.
Page 11 of 16
TYPES OF AIRFLOW CONTROL
Outlet
Dampers
Outlet dampers do not change the characteristics of the entering
airstream. Outlet dampers control flowrate by restricting the
amount of air being discharged. This restriction allows the air flow
rate to be varied the same way a discharge throttle valve adjusts
the volume of flow out of a pump. The resistance of flow through
the system increases as the flow(cfm) of air increases. This
relationship is shown graphically by plotting the flow and
corresponding resistance(pressure) to generate the system
resistance curve. When the system curve and fan performance
curve are shown on the same graph, the intersection of these two
curves defines a unique point of operation. When the fan is
installed in this particular system and operates at this flow rate, it
will produce this pressure. The fan can only operate as shown by
it's performance curve, for a given pressure it will provide a unique
flow or vice versa.
With outlet damper control, any new operating point is achieved
by adjusting the characteristics of the system curve, not the fan
performance curve. For example, in order to reduce the fan flow
rate, as the outlet dampers begin to close, the system's
resistance(pressure) increases and shifts the system curve
upward until it intersects the fan performance curve to define a
new operating point of increased pressure and reduced flow.
Dampers are an efficient method of fully open/closed flow control
such as exhaust air or outside air intakes. Outlet dampers are the
least efficient method of variable flow control. In order for the fan
to compensate for this increase in system pressure when the
dampers begin to close, it has to move to the left up along the
performance curve to the higher operating pressure. For the
majority of fans, as you continue to restrict flow and increase
pressure, the fan operates in the least efficient and unstable
region of the fan performance curve. Operating at higher system
pressures than necessary to reduce the flow rate not only wastes
energy but increases the air leakage throughout the system.
Depending upon the variation in flow rates required by the
system, inlet guide vanes or adjustable speed drives may provide
more energy efficient flow control.
Bonneville Power Administration
Adjustable
Speed-Drives
Adjustable Speed Drives(ASDs) control the flowrate by
electronically adjusting the speed of the motor driving the fan or
pump. Similar to Inlet Guide Vanes, as the speed is reduced, the
flowrate, pressure and horsepower requirement is reduced which
results in a new performance curve for each speed setting. With
ASDs, as speed is reduced the horsepower requirement is
decreased according to the affinity laws within a squared to cubic
relationship depending upon the amount of static pressure and how
the system responds to changes in flow and pressure. A system
containing static head and in which small increases in flow result in
large pressure drops will have a system curve that rises steeply.
By plotting this system curve and a system curve that does not rise
steeply onto the same fan or pump performance curves at various
speeds, one can see the following relationship. That for the same
reduction in flow rate, the system curve that rises steeply will
require more speed reductions to obtain this reduced flow and
therefore the greater the opportunity for energy savings.
In determining the appropriate application of an ASD, the entire
system should be evaluated. For example, if the fan or pump and
electric motor is oversized, further reductions in operating speed
could result in significant reductions in motor efficiency as well as
the efficiencies of the fan, pump. In some cases the motor can be
re-sheaved to confirm energy savings and system response to
reduced speeds prior to purchasing the drive.
ASDs are an excellent choice of flow control if the system allows
the fan or pump to operate at reduced flow rates and loads for a
significant portion of the operating time. The ASDs provide quick
and accurate adjustments to flow rate and pressure as required to
maintain set point. Another advantage of ASD control is their soft
starting capabilities which reduces the high in-rush currents at
start-up. Operating at reduced speeds can increase the equipment
life, reduce vibrations and noise. For fan applications were the flow
rate does not vary significantly, inlet guide vanes may be a better
choice of control. ASDs are not 100% efficient, therefore operating
the motor at full speed with the ASD will increase the input power
due to the inefficiency of the drive. ASDs typically require that they
be placed in a clean, conditioned environment which could result in
high installation costs.
Revision No. 1

Inlet Dampers are usually a better choice of flow control than
Outlet Dampers because when properly installed, they allow the
fan horsepower to be reduced as the flow is reduced. Inlet Guide
Vanes usually provide more accurate control of fan performance
than Inlet Dampers. Inlet Guide Vanes are an efficient method
for controlling flow rates down to approximately 70% of capacity.
This would correspond to a vane position of approximately 50%
Disadvantages
Advantages/
closed. If the desired fan flow rate requires that the vanes be
closed more than 50%, adjustable speed drives usually provide
more efficient controllability by reducing the fan speed rather than
continuing to restrict the fan inlet with the guide vanes.
Inlet Guide Vanes and
Inlet Dampers
Reference: "Improving Fan System Performance" Industrial Technologies and Best Practices Web Site at: http://www.oit.doe.gov
Page 12 of 16
TYPES OF AIRFLOW CONTROL
Dampers are an efficient method of fully open/closed flow control
such as exhaust air or outside air intakes. Outlet dampers are the
least efficient method of variable flow control. In order for the fan
to compensate for this increase in system pressure when the
dampers begin to close, it has to move to the left up along the
performance curve to the higher operating pressure. For the
majority of fans, as you continue to restrict flow and increase
pressure, the fan operates in the least efficient and unstable
region of the fan performance curve. Operating at higher system
pressures than necessary to reduce the flow rate not only wastes
energy but increases the air leakage throughout the system.
Depending upon the variation in flow rates required by the
system, inlet guide vanes or adjustable
Outlet speed drives may provide
more energy efficient flow control.
Dampers
Bonneville Power Administration
ASDs are an excellent choice of flow control if the system allows
the fan or pump to operate at reduced flow rates and loads for a
significant portion of the operating time. The ASDs provide quick
and accurate adjustments to flow rate and pressure as required to
maintain set point. Another advantage of ASD control is their soft
starting capabilities which reduces the high in-rush currents at
start-up. Operating at reduced speeds can increase the equipment
life, reduce vibrations and noise. For fan applications were the flow
rate does not vary significantly, inlet guide vanes may be a better
choice of control. ASDs are not 100% efficient, therefore operating
the motor at full speed with the ASD will increase the input power
due to the inefficiency of the drive. ASDs typically require that they
be placed in a clean, conditioned environment which could result in
Adjustable
high installation costs.
Speed-Drives
Revision No. 1
 Pump Drives Power Graphs

Eddy Current Drive Pump Flow Control ASD Pump Flow Control
120.00 120.00
Outlet Dampers
104.45
100.00 100.00
102.79
% of Design Input Power (kW)

% of Design Input Power (kW)

89.64

80.00 80.00 79.40

75.69

62.77
60.00 60.00 59.53
51.06

43.19
40.00 40.75
40.00
32.01
30.37
25.03
20.00 16.40 17.04
19.98 20.00 21.07
14.32 13.05 15.30

0.00 0.00
0 20 40 60 80 100 120 10 20 30 40 50 60 70 80 90 100 110
% of Design Flow (gpm) % of Design Flow (gpm) or % of Full Speed(rpm)

Mechanical Speed Pump Flow Control

120

104.88 These power curves are used in the energy savings

100
% of Design Input Power (kW)

96.29 analysis. Curves developed from data obtained by

86.46 measuring the operating characteristics of various
80 pumps and from information provided in "Flow
75.81
Control", a Westinghouse publication, Bulletin B-
64.76
60 851, F/86/Rev-CMS 8121. Curves are representative,
53.72 not precise, final economic analysis should be
43.12 based on actual power(kW) measurements of the
40
33.38 pumping system.
24.92
20 18.16
13.51

0
Page 13 of0 16 20 100Bonneville
120 Power Administration Revision No. 1
%40
of Design60Flow (gpm)
80
 53.72

% of Design In
43.12
40
33.38
Pump Drives Power Graphs
24.92
20 18.16
13.51

0
0 20 %40
of Design60Flow (gpm)
80 100 120
Values used in spreadsheet

Page 14 of 16 Bonneville Power Administration Revision No. 1

 ADJUSTABLE SPEED DRIVE ENERGY SAVINGS CALCULATOR
~ Pump Applications ~

Enter Nameplate Horsepower: 100.00 hp

Enter Nameplate Efficiency: 95.00 % www.cerusind.com
Enter Motor Load at Pump Design GPM: 55.00 % 1-800-3543787
Enter Power(KW) at Pump Design GPM: 43.19 KW

Facility Information

Enter Hours per year pump operates: 4000 hrs/yr

Enter Energy Charge: 0.05 $/kwh

Existing Pump Flow Control Method

Select Flow Control
Method Below Click to go to Pump Power Graphs for additional information
1 Throttling Valve 4 Bypass, Recirculation Valve
1 2 Eddy Current Clutch 5 Selection 5 allows Measured Power (kW) readings to be used in
3 Mechanical (Torque Converter) the analysis

Duty Cycle Power Analysis Savings Analysis

Existing System ASD System

Enter
Enter
Percent of Percent of
Percent of Existing Annual Energy Annual Energy Cost
Design Do Not Existing Design
Time at this System ASD System Savings (Kwh/yr) Savings ($/yr)
Capacity Enter Data System Power (kW) for
Capacity Percent of Power (kW)
(GPM) Below (kW) ASD
Design (KW)
System
0.0% 5.0% 55.21 23.85 27.45 11.85 2,398.30 119.92
10.0% 5.0% 61.39 26.52 19.12 8.26 3,651.08 182.55
20.0% 10.0% 67.19 29.02 14.32 6.19 9,133.28 456.66
30.0% 10.0% 72.61 31.36 13.05 5.64 10,289.94 514.50
40.0% 10.0% 77.65 33.54 15.30 6.61 10,772.16 538.61
50.0% 10.0% 82.31 35.55 21.07 9.10 10,579.93 529.00
60.0% 10.0% 86.59 37.40 30.37 13.12 9,713.26 485.66
70.0% 10.0% 90.49 39.08 43.19 18.65 8,172.14 408.61
80.0% 10.0% 94.01 40.60 59.53 25.71 5,956.57 297.83
90.0% 10.0% 97.15 41.96 79.40 34.29 3,066.55 153.33
100.0% 10.0% 99.91 43.15 102.79 44.40 -497.91 -24.90
Totals: 100.0% 142,738.45 Kwh/yr existing 69,503.14 Kwh/yr asd 73,235.31 $ 3,661.77
P erce n t o f T im e at th is C ap ac ity

P ercen t o f T im e at th is C ap acity

Sample Duty Cycles (these can be used as a guide if the duty cycle is not known)
Sample Duty Cycle - HIGH PUMP LOADING Sample Duty Cycle - LOW PUMP LOADING

70 60
55
60
60 50

50
40

40
30
25
30

20 20 20
20 15

10 10
5

0 0
50 75 Capacity (gpm)
Percent of Design 90 30 50of Design Capacity (gpm)
Percent 70 90

Summary

Energy Savings: 73,235.31 KWH/yr Labor Cost: $ -

Cost Savings: $ 3,661.77 Total Cost: $ -
Materials Cost: $ - Simple Payback: years

This calculator was developed by Chris Milan at the Bonneville Power Administration (BPA) and is intended to be used as an estimation of potential energy savings and simple
payback for ASD installations. Final economic decisions should be based upon more extensive analysis tools than what is provided here.

If you have any questions or comments, please email Chris Milan at the following: cbmilan@bpa.gov

* This is an Excel 2000 file and is approximately 2.5 MB in size.

Page 15 of 16 Bonneville Power Administration Revision No. 1

 Throttle Valve Power Graphs

% of Design (kW)
Constant Recirculation, Bypass Control 125 Throttling Valve Flow Control
105
et and Outlet Dampers

100 100 100

97
94
90
87
82
% of Design (kW)

78
95 75 73
67

90 50

85 25

80 0
10 20 30 40 50 60 70 80 90 100 110 10 20 30 40
% of Design Flow (gpm) % of 50 60
Design 70
Flow 80
(gpm) 90 100 110

The power curves above are used in the energy savings analysis. Curves developed from data obtained by measuring the operating characteristics
of various pumps and from information provided in "Flow Control", a Westinghouse publication, Bulliten B-851, F/86/Rev-CMS 8121. Curves are
representative, not precise, final economic analysis should be based on actual power (kW) measurements of the pumping system.

Page 16 of 16 Bonneville Power Administration Revision No. 1