hvac
DESCRIPTION
kokokoTRANSCRIPT
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Course # W 51 HVAC Motor Control SolutionsPresenter: John Polites - Automation Engineer
Wednesday, May 3rd - 9:00 AM 10:00 AM
State College Room
Topics of Discussion:Motor Load & Starting Methods Motor Control for HVAC ApplicationsEnergy Savings with Variable Frequency DrivesIntroduction to PF400 HVAC Drive
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AC MOTOR LOADS
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Constant Torque
Variable Torque
Constant HorsepowerAC Motor Load Types
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Constant Torque Motor Loads
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Variable Torque Motor Loads
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Typical of Centrifugal Pumps and FansPumps: Hot Water, Chilled Water, Condenser Water, DistributionFans: Supply, Return, Relief, Exhaust, Cooling Tower FansTorque and Horsepower Drops As Square of Speed Reduction; Excellent Potential for Energy Savings with a VFD versus a throttling Valves, Dampers or Inlet Vanes
Variable Torque Application Types
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Two Pump Types:
Positive Displacement Pumps Move fluid chamber to cause fluid to flow Constant Torque Load Profile Centrifugal Pumps Move fluid by rotation of an impeller Variable Torque Load Profile Hydronic Pumps: Hot Water, Chilled Water, Condenser Water & Distribution
HVAC Pump Types
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Components of the Pump SystemPumpMotorCouplingBase PlatePipingValvesInlet SourceAbove PumpBelow PumpDischarge Static Head
Start
Version 1.3.0
Version Date 1/16/2002
Centrifugal Pump Energy Savings Calculator
This tool is designed to compare conventional flow control methods with variable speed control and
show the differential of power consumption of each.
Having the pump specifications and flow rates will result in the most accurate calculated energy
costs. If the pump specifications are unkown, a generic curve can be created.
Use the buttons below to navigate to the appropriate sheets in this workbook.
The cells have been color coded as follows:
Data Entry CellsPROJECT INFORMATIONChoose 1 of the calculators below
Calculated Data CellsHELP INSTRUCTIONSBASIC
Active HyperlinksPUMP TUTORIAL DOCUMENTINTERMEDIATE
Other colors are used as referencesHOW TO READ A PUMP CURVEADVANCED
Help Notes:
PUMP TUTORIAL DOCUMENT
This hyperlink must "point" to the documents "Pump Fundamentals.doc".
To ensure that this document can be accessed, file it in the same directory as this spreadsheet.
HOW TO READ A PUMP CURVE
The hyperlink takes you to the sheet labeled "Reading Pump Curves". This sheet describes
all of the information that is represented on the curve and how to interpret the data.
BASIC
This hyperlink goes to the sheet labled "Quick Calculator". Use this when only the motor
rating is known and flow and pressure data can be entered as a percentage. This allows
you to quickly show how a pump system can benefit by using a VFD to reduce speed
to control the flow rather than a throttling valve.
INTERMEDIATE
This hyperlink takes you to the sheet labeled "Unknown Pump". Use this sheet when flow
and pressure values are known, but the pump size is not. A "generic" pump and system
curve are plotted from the data entered.
ADVANCED
This hyperlink jumps to the sheet labeled "Known Pump". The pump data must be known
to use this sheet. A drop-down box contains a list of pump sizes to choose from.
The database of pump curves is located on the sheet labeled "Pump Curves". If your
specific pump size is not in the list, it can be added with minor changes.
RETURN
The data below will be referenced on the report.
Fill in the information you wish to display on the report.
Date:15-Jan-02
Prepared By:your name here
Customer:customer name
Project:project name/number
Pump:pump name/number
Changes for Version 1.3.0
1. Fixed pump curve for both the "basic" and "Intermediate" calculators
2. "Basic" report charts were plotting the wrong data cells, fixed chart data.
3. Added a "bypass" flow summary to the "Intermediate" calculator. (Rated kW *Annual Hours*Cost/kWhr)
&R&D
Rockwell Automation:Enter application data in these cells.
Rockwell Automation:These cells contain formulas, and are protected from editing.
Rockwell Automation:These cells are "hyperlinks" to specify locations within the workbook. Click to jump to the link location.
Rockwell Automation:Click here for instructions on this spreadsheet.
Rockwell Automation:Click to return to "Start".
Rockwell Automation:Other colors are used, but only to define references for the worksheet. These cells are protected from editing.
Rockwell Automation:Click here for pump terms and fundamentals.
Rockwell Automation:Click here for a tutorial on how to read data supplied on a pump curve.
Rockwell Automation:Click here to estimate energy savings potential when only the Motor rating is known. Flow and pressure data is entered in %.
Rockwell Automation:Click here to create a generic pump curve from flow and pressure data and calculate Brake HP. Flow and pressure data entered in GPM and Head.
Rockwell Automation:Click here to select a pump curve from a library. The pump curve and system parameters are entered in GPM and HEAD.
Rockwell Automation:Click to enter project information you wish to display on the report.
RETURN
PUMP TUTORIAL DOCUMENT
HOW TO READ A PUMP CURVE
BASIC
INTERMEDIATE
ADVANCED
HELP INSTRUCTIONS
PROJECT INFORMATION
Known Pump
Advanced CalculatorFlow (Rated/Min)Linearized efficiency table for flow rates selected with Throttled system (Min Flow / Rated Flow)
ReturnPaste Pump Curve Inside this border.0.444Decimal95%90%85%80%75%70%65%60%55%50%45%40%35%30%25%20%
Pump DataValueUnitsThrottling Valve44.44%0000000000010000
Select the Diameter of the Outlet x Inlet - Impeller3 x 4 - 7inchesPaste Pump Curve inside border.% FlowGPMWHPBHPPump EffHead FtTotal HeadPump Eff% Flow
Pump speed3560RPM100%450.020.6828.7272172182720.00.00.00.00.00.00.00.00.00.00.072.00.00.00.00.0100%
Rated Flow450GPM95%427.518.8926.2470.6175185720.00.00.00.00.00.00.00.00.00.00.070.60.00.00.00.095%
Minimum Flow200GPM90%405.00.000.0069.20000.00.00.00.00.00.00.00.00.00.069.20.00.00.00.090%
Static Head10Ft85%382.50.000.0067.800710.00.00.00.00.00.00.00.00.067.80.00.00.00.085%
Pressure @ Rated Flow172Ft80%360.00.000.0066.50000.00.00.00.00.00.00.00.066.50.00.00.00.080%
Pressure @ Min Flow205Ft75%337.50.000.0065.10000.00.00.00.00.00.00.065.10.00.00.00.075%
Pump Efficiency70%315.015.5123.5063.7195205660.00.00.00.00.00.063.70.00.00.00.070%
@ Rated Flow72%65%292.50.000.0062.30000.00.00.00.00.062.30.00.00.00.065%
@ Minimum Flow54%60%270.013.6422.7360.9200210600.00.00.00.060.90.00.00.00.060%
Specific Gravity1in Hg55%247.50.000.0059.50000.00.00.059.50.00.00.00.055%
Annual Operating Time8760Hours50%225.011.5920.7058.2204214560.00.058.20.00.00.00.050%
Cost per kilowatt Hour7Cents45%202.510.4819.4156.8205215540.056.80.00.00.00.045%
Motor DataUnits40%180.00.000.0054.000054.00.00.00.00.040%
Rated Power30HP35%157.50.000.000.00000.00.00.00.035%
Base Speed3600RPM30%135.00.000.000.00000.00.00.030%
Efficiency92.4%25%112.50.000.000.000000.025%
Calculated Data20%90.00.000.000.0000020%
Brake HP @ Rated Flow28.72BHP
Water HP @ Rated Flow20.68WHPAB Drive
Brake HP @ Min Flow20.11BHP% FlowGPMWHPBHPPump EffHead FtStatic HeadTotal HeadVel ft/secRPMMotor EffDrive EffEff FactorInput HPkWHoursAnnual $
Water HP @ Min Flow10.86WHP100%450.020.6827.157217210.00172.00108.82356092.498.5128.9421.59876$1,323.79
Pump Efficiency Selection95%427.517.9223.4272165.9510.00156.21103.38338292.271168592798.250.99860624.9418.60876$1,140.80
90%405.015.2320.0672148.9410.00141.2297.94320492.1422422536980.99721021.3315.9200.0
85%382.512.8317.0472132.8510.00127.0592.50302691.984297.760.995518.1113.5100.0
Flow Rate% Time atHeadPump % EffFlowClick to select Pump CurveNOTE: If a Pump Curve is present80%360.010.7014.3572117.6810.00113.6887.06284891.845697.50.99415.2411.3700.0
GPMFlowFtfrom Curve%above, it must be deleted prior to75%337.58.8211.9772103.4310.00101.1381.62267091.71264610297.20.99256112.699.4600.0
90020pasting another curve.70%315.07.179.877290.1010.0089.3876.17249291.34386896.920.9885710.487.821752$958.58
113025View Report65%292.55.748.057277.6910.0078.4570.73231490.9770496.680.98468.556.3800.0
13503060%270.04.516.477266.2010.0068.3265.29213690.58942296.420.9804056.895.141752$630.01
15803555%247.53.485.127255.6210.0059.0159.85195890.1315896.20.975455.474.0800.0
180040Summary50%225.02.613.997245.9710.0050.5054.41178089.74877788895.90.9713074.263.181752$389.59
203202055445Control MethodAnnual $45%202.51.903.047237.2410.0042.8148.97160288.864960894.50.9617423.232.411752$295.78
225202045650Throttling Valve$11,270.0540%180.01.342.277229.4210.0035.9243.53142487.97727493.170.9521352.401.7900.0
248055VFD Control$4,738.5435%157.50.901.657222.5310.0029.8538.09124686.85691.80.941.741.3000.0
270202006060Savings with VFD$6,531.5030%135.00.561.167216.5510.0024.5832.65106885.92183690.150.929891.220.9100.0
29306525%112.50.330.797211.4910.0020.1327.2189085.035494174488.70.9202980.830.6200.0
315201956670If a #DIV/0! error occurs, verify that20%90.00.170.52727.3610.0016.4821.7671280.524567280.260.8714780.520.3900.0
338075a pump efficiency has been entered forTOTAL$4,738.54
360080each flow rate that is used.
38307185
405090
428101757295
4501017272100Power requirements for different control methods
Total100%Throttled
% FlowBHPMotor EffInput HPkWhoursAnnual $
100%28.7292.4031.0923.19876$1,422.08
Calculate using values entered in cells B12 & B1395%26.2492.4028.4021.18876$1,299.02
Enter each value from pump curve90%0.0092.400.000.0000.0
285%0.0092.400.000.0000.0
7Pumprpm80%0.0092.400.000.0000.0
Pump Curve FilePump SizeChosenPump Speedcodepump #pump sizepump rpm75%0.0092.400.000.0000.0
21003.pdf1 x 1.5 - 8081100 - 120011 x 1.5 - 8350070%23.5092.4025.4418.971752$2,327.05
21104.pdf1 x 2 - 100101700 - 180021 x 2 - 10356065%0.0092.400.000.0000.0
22285.pdf2 x 3 - 6063500 - 360032 x 3 - 6350060%22.7392.4024.6018.351752$2,250.33
15864.pdf2 x 3 - 80842 x 3 - 8356055%0.0092.400.000.0000.0
50241.pdf2 x 3 - 10010345052 x 3 - 10356050%20.7092.4022.4016.711752$2,049.41
38303.pdf2 x 3 - 13013350062 x 3 - 13357045%19.4192.4021.0115.671752$1,922.16
26803.pdf3 x 4 - 717356073 x 4 - 7356040%0.0092.400.000.0000.0
15923.pdf3 x 4 - 80883 x 4 - 8355035%0.0092.400.000.0000.0
16168.pdf3 x 4 - 1001093 x 4 - 10356030%0.0092.400.000.0000.0
23362.pdf3 x 4 - 13013103 x 4 - 13357025%0.0092.400.000.0000.0
53790.pdf4 x 6 - 10010114 x 6 - 10356020%0.0092.400.000.0000.0
16895.pdf1.5 x 3 - 10010121.5 x 3 - 103560TOTAL$11,270.05
49881.pdf1.5 x 3 - 13013131.5 x 3 - 133560
19261.pdf8 x 10 -22022148 x 10 -221780
18522.pdf10 x 12 - 220221510 x 12 - 221785
19382.pdf12 x 14 - 180181612 x 14 - 181780
25391.pdf16 x 18 - 300301716 x 18 - 301190
31452.pdf18 x 20 - 240241818 x 20 - 241190
17477.pdf18 x 20 - 300301918 x 20 - 301190
Goes to B4
3 x 4 - 73 x 4 - 7
0Goes to B5
03560
08
010
06
77
013
018
022
024
030
Impeller diameter check7
Static Head
This is simply the elevation change from the source to the destination.
The elevation change is a measurement of pressure in feet of Head.
Example:
If a system raises the liquid being pumped by 14ft of elevation from the
source to the destination, a value of 14 is the static Head.
BACK
Rockwell Automation:Click to Return to "START".
Rockwell Automation:Click Here to lookup values for various liquids.
Rockwell Automation:Click here to lookup motor efficiency from table.
Rockwell Automation:BHP = Rated Flow x Pressure x Sp. Gr./ Eff x 3960
Rockwell Automation:WHP = Rated Flow x Pressure x Sp. Gr./ 3960
Rockwell Automation:Enter the value indicated on the graph for the specified flow.
Rockwell Automation:Enter the value indicated on the graph for the specified flow.
Rockwell Automation:BHP = Rated Flow x Pressure x Sp. Gr./ Eff x 3960
Rockwell Automation:WHP = Rated Flow x Pressure x Sp. Gr./ 3960
Rockwell Automation:whp = gpm*head*sp.gr/3960
Rockwell Automation:bhp = gpm*head*sp.gr./3960*pump eff.
Rockwell Automation:whp = gpm*head*sp.gr/3960
Rockwell Automation:bhp = gpm*head*sp.gr./3960*pump eff.
Rockwell Automation:rpm = pump rpm*%flow
Rockwell Automation:Velocity of impeller in ft/secV=rpm*diameter/229
Rockwell Automation:H= V^2/2gwhere:V is veleocity (ft/sec)g is 32.2 (ft/sec^2)
Rockwell Automation:NEED TO VERIFY EFFICIENCY AT VARIOUS SPEEDS OF PUMP!
Rockwell Automation:Static Head for the given flow that will be added to calculated head.
Rockwell Automation:Static Head + Dynamic Head for each operating speed of the pump.
Rockwell Automation:Pump Efficiency - based on "Pump Efficiency Selection" list.
Rockwell Automation:Click here to view report.
Rockwell Automation:Click to go back to previous location.
Rockwell Automation:For more information click this cell.
Return
Specific Gravity
Efficiency
View Report
BACK
Static Head
Click to select Pump Curve
Known Pump Report
Return
Centrifugal Pump Energy Savings Report
Pump DataValueUnits
Inlet, Outlet, Impeller Size3 x 4 - 7inches
Pump Speed3560RPM
Rated Flow450GPM
Minimum Flow200GPM
Static Head10Ft
Pressure @ Rated Flow172Ft
Pressure @ Min Flow205Ft
Pump Efficiency
@ Rated Flow72%
@ Minimum Flow54%
Specific Gravity1in Hg
Annual Operating Time8760Hours
Cost per kilowatt Hour7Cents
Motor DataUnits
Rated Power30HP
Base Speed3600RPM
Efficiency92.4%
Calculated Data
Brake HP @ Rated Flow28.72BHP
Water HP @ Rated Flow20.68WHP
Brake HP @ Min Flow20.11BHP
Water HP @ Min Flow10.86WHP
Flow Profile
Flow Rate as% Time atHeadThrottling Valve ControlVFD Control
Percent of ratedFlowFtFlow (GPM)Pump BHPMotor EffMotor HPMotor kWHoursAnnual $Pump BHPEfficiencyMotor HPMotor kWHoursAnnual $
100%1017245028.7292.4031.0923.19876.001422.0827.1591.0128.9421.59876.001323.79
95%10175427.526.2492.4028.4021.18876.001299.0223.4290.6624.9418.60876.001140.80
90%004050.0092.400.000.000.000.0020.0690.3021.3315.920.000.00
85%00382.50.0092.400.000.000.000.0017.0489.9218.1113.510.000.00
80%003600.0092.400.000.000.000.0014.3589.5515.2411.370.000.00
75%00337.50.0092.400.000.000.000.0011.9789.1412.699.460.000.00
70%2019531523.5092.4025.4418.971752.002327.059.8788.5310.487.821752.00958.58
65%00292.50.0092.400.000.000.000.008.0587.968.556.380.000.00
60%2020027022.7392.4024.6018.351752.002250.336.4787.356.895.141752.00630.01
55%00247.50.0092.400.000.000.000.005.1286.715.474.080.000.00
50%2020422520.7092.4022.4016.711752.002049.413.9986.074.263.181752.00389.59
45%20205202.519.4192.4021.0115.671752.001922.163.0483.983.232.411752.00295.78
40%001800.0092.400.000.000.000.002.2781.972.401.790.000.00
35%00157.50.0092.400.000.000.000.001.6579.731.741.300.000.00
30%001350.0092.400.000.000.000.001.1677.461.220.910.000.00
25%00112.50.0092.400.000.000.000.000.7975.430.830.620.000.00
20%00900.0092.400.000.000.000.000.5264.630.520.390.000.00
Total$11,270.05Total$4,738.54
Savings per Year$6,531.50$ US
Date:1/15/02By:your name here
Customer:customer nameProject:project name/numberPump:pump name/number
Page 1 of 2
Centrifugal Pump Energy Savings Report
Insert pump curve here for reportThe pump curve shown at left was used for the
energy savings analysis.
Some of the key points to operating the pump
at constant speed with a throttling valve to
control flow are shown by the pressure vs. flow
characteristic curve. In order to reduce flow, the
pressure increases. The efficiency of the pump will
also change as shown by the "U" shaped efficiency.
curves.
Conversely, operating the pump at variable speed
has several advantages. The first is a reduced
pressure with reduced flow. The dynamic pressure
where:
H = head in ft
Therefore, by reducing the velocity of the pump,
the pressure reduces by the square. The efficiency
of the pump also remains relatively constant.
The Brake HP required to pump at a given flow
is determined by the following formula.
BHP = GPM x Head x Specific Gravity/ 3960 x eff
Date:1/15/02By:your name here
Customer:customer nameProject:project name/numberPump:pump name/number
Page 2 of 2
Known Pump Report
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Throttling Valve
VFD
Flow (GPM)
Input Power (kW)
VFD vs Throttling Valve Control
Unknown Pump
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Throttling Valve
VFD
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Operating Cost per Year
Unknown Pump Report
Intermediate CalculatorFlow (Min/Rated)Linearized efficiency table for flow rates selected with Throttled system (Min Flow / Rated Flow)
Return0.489Decimal95%90%85%80%75%70%65%60%55%50%45%40%35%30%25%20%
Pump DataValueUnitsThrottling Valve48.91%0000000000100000
Pump Rated Speed1185RPM% FlowGPMWHPBHPPump EffHead FtTotal HeadPump Eff% Flow
Rated Flow6000GPM100%6000.0196.97246.5279.9130260.079.90.00.00.00.00.00.00.00.00.00.079.90.00.00.00.00.0100%
Minimum Flow2934.5GPM95%5700.0198.70255.0477.9138.0268.077.90.00.00.00.00.00.00.00.00.00.077.90.00.00.00.00.095%
Static Head20Ft90%5400.0198.65261.6775.9145.7275.775.90.00.00.00.00.00.00.00.00.075.90.00.00.00.00.090%
Pressure @ Rated Flow130Ft85%5100.0196.91266.3673.9152.9282.973.90.00.00.00.00.00.00.00.073.90.00.00.00.00.085%
Pressure @ Min Flow181Ft80%4800.0193.58269.1071.9159.7289.771.90.00.00.00.00.00.00.071.90.00.00.00.00.080%
Pressure @ Zero Flow212.5Ft75%4500.0188.74269.8669.9166.1296.169.90.00.00.00.00.00.069.90.00.00.00.00.075%
Pump Efficiency70%4200.0182.50268.5968.0172.1302.168.00.00.00.00.00.068.00.00.00.00.00.070%
@ Rated Flow79.9%65%3900.0174.95265.2566.0177.6307.666.00.00.00.00.066.00.00.00.00.00.065%
@ Minimum Flow56%60%3600.0166.18259.7964.0182.8312.864.00.00.00.064.00.00.00.00.00.060%
Specific Gravity1in Hg55%3300.0156.29252.1862.0187.5317.562.00.00.062.00.00.00.00.00.055%
Annual Operating Time8760Hours50%3000.0145.36242.3360.0191.9321.960.00.060.00.00.00.00.00.050%
Cost per kilowatt Hour4Cents45%2700.0133.50238.3956.0195.8325.856.056.00.00.00.00.00.045%
Motor DataUnits40%2400.0120.790.000.0199.3329.30.00.00.00.00.00.040%
Rated Power200HP35%2100.0107.330.000.0202.4332.40.00.00.00.00.035%
Base Speed1185RPM30%1800.093.220.000.0205.1335.10.00.00.00.030%
Efficiency86.8%25%1500.078.540.000.0207.3337.30.000.025%
Calculated Data20%1200.063.390.000.0209.2339.20.0020%
Brake HP @ Rated Flow246.52HP
Water HP @ Rated Flow196.97HPAB Drive
% FlowGPMWHPBHPPump EffHead FtStatic HeadTotal HeadVel ft/secRPMMotor EffDrive EffEff FactorInput HPkWHoursAnnual $
Flow Rate% TimeHead100%6000.0196.97246.5279.913020.00130.000.00086.898.51279.75208.69876$7,312.60
GPMat Flow(Ft)95%5700.0198.70214.8779.9138.0420.00119.280.00086.678976556898.250.998606243.56181.69788.4$5,729.89
12000209.290%5400.0198.65186.2079.9145.6820.00109.100.00086.5578639352980.997210210.81157.27788.4$4,959.54
15000207.385%5100.0196.91160.3479.9152.8920.0099.480.00086.409497.760.9955181.40135.33788.4$4,267.64
18000205.180%4800.0193.58137.1479.9159.7020.0090.400.00086.279297.50.994154.98115.61788.4$3,645.96
21000202.475%4500.0188.74116.4579.9166.0920.0081.880.00086.15430391497.20.992561131.3798.01788.4$3,090.70
24000199.370%4200.0182.5098.1079.9172.0820.0073.900.00085.80787696.920.98857110.8082.66788.4$2,606.65
27000195.8View Report65%3900.0174.9581.9479.9177.6420.0066.480.00085.4632896.680.984692.6969.15788.4$2,180.64
30009191.960%3600.0166.1867.8179.9182.8020.0059.600.00085.09915496.420.98040576.8357.32788.4$1,807.57
33009187.5Summary55%3300.0156.2955.5679.9187.5420.0053.280.00084.6690696.20.9754563.1347.10788.4$1,485.22
36009182.8Control MethodAnnual $50%3000.0145.3645.0479.9191.8820.0047.500.00084.30945801695.90.97130751.2338.22788.4$1,205.20
39009177.6Throttling Valve$78,168.7445%2700.0133.5036.0779.9195.7920.0042.280.00083.479205694.50.96174240.8430.4600.0
42009172.1VFD Control$38,291.6240%2400.0120.7928.5279.9199.3020.0037.600.00082.64531893.170.95213532.1523.9900.0
45009166.1Savings with VFD$39,877.1235%2100.0107.3322.2279.9202.3920.0033.480.00081.59291.80.9425.0018.6500.0
48009159.730%1800.093.2217.0179.9205.0820.0029.900.00080.71445290.150.9298919.0014.1700.0
51009152.9Summary25%1500.078.5412.7479.9207.3420.0026.880.00079.881827860888.70.92029814.1510.5500.0
54009145.7Control MethodAnnual $20%1200.063.399.2579.9209.2020.0024.400.00075.644290480.260.8714789.827.3200.0
57009138.0Bypass$74,239.64TOTAL$38,291.62
600010130.0VFD Control$38,291.62
Total100%Savings with VFD$35,948.02
Power requirements for different control methods
ThrottledBypass
Brake HP @ Min Flow239.51HP% FlowBHPMotor EffInput HPkWhoursAnnual $% FlowBHPMotor EffInput HPkWhoursAnnual $
Water HP @ Min Flow134.13HP100%246.5286.80284.01211.87876$7,423.96100%246.5286.80284.01211.878760$74,239.64
95%255.0486.80293.83219.20788.4$6,912.55TOTAL$74,239.64
90%261.6786.80301.46224.89788.4$7,092.06
85%266.3686.80306.87228.92788.4$7,219.37
80%269.1086.80310.03231.28788.4$7,293.68
75%269.8686.80310.90231.93788.4$7,314.09
70%268.5986.80309.43230.83788.4$7,279.61
65%265.2586.80305.58227.97788.4$7,189.11
60%259.7986.80299.30223.28788.4$7,041.34
55%252.1886.80290.53216.73788.4$6,834.87
50%242.3386.80279.19208.27788.4$6,568.10
45%238.3986.80274.64204.8800.0
40%0.0086.800.000.0000.0
35%0.0086.800.000.0000.0
30%0.0086.800.000.0000.0
25%0.0086.800.000.0000.0
20%0.0086.800.000.0000.0
TOTAL$78,168.74
Static Head
This is simply the elevation change from the source to the destination.
The elevation change is a measurement of pressure in feet of Head.
Example:
If a system raises the liquid being pumped by 14ft of elevation from the
source to the destination, a value of 14 is the static Head.
BACK
Specific Gravity
MaterialSp. Gr.
Acetone0.79
Alcohol, Ethyl0.789
Alcohol, Methyl0.791
Brine1.2
Aviation Gasoline0.72
Cement Slurry1.44
Crude Oil0.85
Diesel Fuel0.84
Gasoline0.74
Hydraulic Fluid0.86
Jet Fuel, JP-40.78
Water1.0
Sea Water1.03
Rockwell Automation:Click to return to worksheet
Unknown Pump Report
212.5020
212.293750.32520.275
211.6751.321.1
210.643752.92522.475
209.25.224.4
207.343758.12526.875
205.07511.729.9
202.3937515.92533.475
199.320.837.6
195.7937526.32542.275
191.87532.547.5
187.5437539.32553.275
182.846.859.6
177.6437554.92566.475
172.07563.773.9
166.0937573.12581.875
159.783.290.4
152.8937593.92599.475
145.675105.3109.1
138.04375117.325119.275
130130130
Pump Curve
System Curve
System Curve with Static Head
Pump Curves
Pump DataValueUnits% Rated Flow
Pump Speed1185RPM49%@ Min FlowGravity (ft/sec^2)V = rpm * (D/229)
Rated Flow6000GPM32.2where:V = velocity (ft/sec)Centrifugal Pump Energy Savings ReportReturn
Minimum Flow2934.5GPMD = impeller diameter
Static Pressure20Ftimpeller dia (in)Pump DataValueUnits
Pressure @ Rated Flow130Ftchange pump curve slope ->5H = v^2/2gPump Speed1185RPM
Pressure @ Min Flow181Ftwhere:H = pressure (ft)Rated Flow6000GPM
Pressure @ Zero Flow212.5Ftpipe IDv = velocity (ft/sec)Minimum Flow2934.5GPM
Specific Gravity1in hg3g = gravity (ft/sec^2)Static Head20Ft
System Curve CalculationAff. Law + FactorAff. Law + S.H.Pressure @ Rated Flow130Ft
Flow Rate asTime atFlowPump CurveSys Curve (ft)Static PressureImpellerVelocitySys Curve (ft)pumpSys Curve (ft)Sys Curve (ft)Sys Curve (ft)Sys Curve (ft)pumpPressure @ Min Flow181Ft
Percent of ratedFlowUnitsGPMFt of HeadAff. LawsFt of HeadRPMft/seccurvew/ Static Headw/ Static Headw/ Static Headw/ Static HeadcurvePressure @ Zero Flow212.5Ft
0%0%0.0212.502000.00.0212.520.020.020.020.020212.50%Pump Efficiency
5%0%300.0208019.992857142959.251.30.0212.420.020.320.320.319212.295%@ Rated Flow79.9%
10%0%600.0204119.95118.52.60.1212.420.121.321.321.118211.6810%@ Minimum Flow56%
15%0%900.0200319.775177.753.90.2212.320.022.722.922.517210.6415%Specific Gravity1in Hg
20%0%1200.0196519.54285714292375.20.4212.220.024.725.224.416209.20020%Annual Operating Time8760Hours
25%0%1500.0192819.1666666667296.256.50.6212.119.827.328.126.915207.34025%Cost per kilowatt Hour4Cents
30%0%1800.01881218.56355.57.80.9212.019.530.331.729.914205.08030%Motor DataUnits
35%0%2100.01841617.7727272727414.759.11.3211.919.033.735.933.513202.39035%Rated Power200HP
40%0%2400.01802116.847410.31.7211.718.537.640.837.612199.30040%Base Speed1185RPM
45%0%2700.01752615.95533.2511.62.1211.518.142.346.342.311195.79145%Efficiency86.8%
50%9%3000.01713315592.512.92.6211.317.647.552.547.510191.88050%Calculated Data
55%9%3300.01673913.95651.7514.23.1211.117.153.359.353.39187.54055%Brake HP @ Rated Flow246.52BHP
60%9%3600.01634712.871115.53.7210.816.559.666.859.68182.80060%Water HP @ Rated Flow196.97WHP
65%9%3900.01595511.55770.2516.84.4210.415.966.574.966.57177.64065%Brake HP @ Min Flow239.51BHP
70%9%4200.01556410.2829.518.15.1209.915.373.983.773.96172.08070%Water HP @ Min Flow134.13WHP
75%9%4500.0151738.75888.7519.45.8209.314.681.993.181.95166.09075%Flow Profile
80%9%4800.0147837.294820.76.7208.413.990.4103.290.44159.70080%Flow Rate as% Time atHeadThrottling Valve ControlVFD Control
85%9%5100.0142945.551007.2522.07.5207.713.199.5113.999.53152.89085%Percent of ratedFlowFtFlow (GPM)Pump BHPMotor EffMotor HPMotor kWHoursAnnual $Pump BHPEfficiencyMotor HPMotor kWHoursAnnual $
90%9%5400.01381053.81066.523.38.4206.812.2109.1125.3109.12145.68090%100%10130.06000.0246.5286.80284.01211.87876.007423.96246.5285.50279.75208.69876.007312.60
95%9%5700.01341171.951125.7524.69.4205.511.3119.3137.3119.31138.04095%95%9138.05700.0255.0486.80293.83219.20788.406912.55214.8785.16243.56181.69788.405729.89
100%10%6000.01301300118525.910.4130.010.4130.0150.0130.00130.090%9145.75400.0261.6786.80301.46224.89788.407092.06186.2084.83210.81157.27788.404959.54
Total % Time at Flow10085%9152.95100.0266.3686.80306.87228.92788.407219.37160.3484.47181.40135.33788.404267.64
80%9159.74800.0269.1086.80310.03231.28788.407293.68137.1484.12154.98115.61788.403645.96
Affinity Laws75%9166.14500.0269.8686.80310.90231.93788.407314.09116.4583.74131.3798.01788.403090.70
Q1/Q2 = N1/N270%9172.14200.0268.5986.80309.43230.83788.407279.6198.1083.16110.8082.66788.402606.65
65%9177.63900.0265.2586.80305.58227.97788.407189.1181.9482.6392.6969.15788.402180.64
60%9182.83600.0259.7986.80299.30223.28788.407041.3467.8182.0576.8357.32788.401807.57
Q = Flow Rate55%9187.53300.0252.1886.80290.53216.73788.406834.8755.5681.4563.1347.10788.401485.22
N = Pump Speed50%9191.93000.0242.3386.80279.19208.27788.406568.1045.0480.8551.2338.22788.401205.20
H = Total Head45%0195.82700.0238.3986.80274.64204.880.000.0036.0778.8940.8430.460.000.00
P = Input Power40%0199.32400.00.0086.800.000.000.000.0028.5277.0032.1523.990.000.00
35%0202.42100.00.0086.800.000.000.000.0022.2274.9025.0018.650.000.00
30%0205.11800.00.0086.800.000.000.000.0017.0172.7619.0014.170.000.00
25%0207.31500.00.0086.800.000.000.000.0012.7470.8614.1510.550.000.00
20%0209.21200.00.0086.800.000.000.000.009.2560.719.827.320.000.00
Total$78,168.74Total$38,291.62
Savings per Year$39,877.12$ US
Date:1/15/02By:your name here
Customer:customer nameProject:project name/numberPump:pump name/number
Page 1 of 1
Rockwell Automation:Click to return to "Start".
Rockwell Automation:whp = gpm*head*sp.gr/3960
Rockwell Automation:bhp = gpm*head*sp.gr./3960*pump eff.
Rockwell Automation:Pump Efficiency - based on "Pump Efficiency Selection" list.
Rockwell Automation:whp = gpm*head*sp.gr/3960
Rockwell Automation:bhp = gpm*head*sp.gr./3960*pump eff.
Rockwell Automation:NEED TO VERIFY EFFICIENCY AT VARIOUS SPEEDS OF PUMP!
Rockwell Automation:H= V^2/2gwhere:V is veleocity (ft/sec)g is 32.2 (ft/sec^2)
Rockwell Automation:Static Head for the given flow that will be added to calculated head.
Rockwell Automation:Static Head + Dynamic Head for each operating speed of the pump.
Rockwell Automation:Velocity of impeller in ft/secV=rpm*diameter/229
Rockwell Automation:rpm = pump rpm*%flow
Rockwell Automation:Click here for report
Rockwell Automation:Enter the efficiency of the pump when operated at the rated flow rate.5-30HP typical 45-72%40-150HP typical 55-75%200HP & Up typical 75-90%
Rockwell Automation:Enter the efficiency of the pump when operated at the minimum flow rate.5-30HP typical 25-55%40-150HP typical 30-60%200HP & Up typical 55-80%
Rockwell Automation:Click to go back to previous location.
Rockwell Automation:For more information click this cell for a description.
Rockwell Automation:To look up the specific gravity of different liquids, click this cell. The Specific Gravity of Water is 1.0
Rockwell Automation:The pressure is a resistance to flow and is meadsured in feet of head. Formula:Feet of Head = p.s.i. x 2.31 / specific gravity
Rockwell Automation:The value entered for Motor Base Speed will be used as the Pump Rated Speed.
Rockwell Automation:This value should reflect the rated flow for the system. It is used to calculate HP requirements.HP = Flow x Head / 3960
Rockwell Automation:Enter the minimum flow rate for the system.
Rockwell Automation:Enter a value that is greater than "Pressure @ Rated Flow. This value is used to calculate HP requirements.
Rockwell Automation:Value should be equal to or greater than the Pressure @ Min Flow. This value is used to draw the pump curve on the graph.
Pump Curves
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Pump Curve
System Curve with Static Head
System Curve no Static Head
Flow GPM
Head ft
Formulas & Tables
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Throttling Valve
VFD
Flow (GPM)
Input Power (kW)
VFD vs Throttling Valve Control
Quick Calculator
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Throttling Valve
VFD
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US Dollars
Operating Cost per Year
Quick Calc Report
The Pump Chosen is:3 x 4 - 7
The RPM is:3560
Go to the specific cell below and "click" to see the pump curve.
Pump Curve Library
Return3500 - 3600 RPM1700 - 1800 RPM1100 - 1200 RPM
Pump Size 1 x 1.5 - 811 x 1.5 - 8
021 x 2 - 10
32 x 3 - 6
42 x 3 - 8
52 x 3 - 10
62 x 3 - 13
73 x 4 - 7
83 x 4 - 8
93 x 4 - 10
103 x 4 - 13
114 x 6 - 10
121.5 x 3 - 10
131.5 x 3 - 13
148 x 10 -22
1510 x 12 - 22
1612 x 14 - 18
1716 x 18 - 30
1818 x 20 - 24
1918 x 20 - 30
Pump Size 1 x 2 - 10ReturnPump Size 8 x 10 - 22ReturnPump Size 16 x 18 - 30Return
000
Pump Size 2 x 3 - 6ReturnPump Size 10 x 12 - 22ReturnPump Size 18 x 20 - 24Return
000
Pump Size 2 x 3 - 8ReturnPump Size 12 x 14 - 18ReturnPump Size 18 x 20 - 30Return
000
Pump Size 2 x 3 - 10Return
0
Pump Size 2 x 3 - 13Return
0
Pump Size 3 x 4 - 7Return
Select the drawing below and copy it - then click Return.
Pump Size 3 x 4 - 8Return
0
Pump Size 3 x 4 - 10Return
0
Pump Size 3 x 4 - 13Return
0
Pump Size 4 x 6 - 10Return
0
Pump Size 1.5 x 3 - 10
0
Pump Size 1.5 x 3 - 13
0
Rockwell Automation:Click here to return
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Rockwell Automation:Click to return to "Known Pump" data entry sheet.
Return
Return
Return
Return
Return
Return
Return
Return
Return
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Return
1 x 1.5 - 8
1 x 2 - 10
2 x 3 - 6
2 x 3 - 8
2 x 3 - 10
2 x 3 - 13
3 x 4 - 7
3 x 4 - 8
3 x 4 - 10
3 x 4 - 13
4 x 6 - 10
1.5 x 3 - 10
1.5 x 3 - 13
8 x 10 -22
10 x 12 - 22
12 x 14 - 18
16 x 18 - 30
18 x 20 - 24
18 x 20 - 30
Reading Pump Curves
ReturnReturn
Motor EfficienciesSpecific GravityEddy Current Clutch
1800 RPMStd Eff.1329 OPD1329 TEFCMaterialSp. Gr.% FlowAffinity HpEfficiency% MAX GPM Pres.Pressure w/ mech. restriction selected0000
Rated HP% Eff% Eff% EffAcetone0.790%0%0% Flow=
174.4%82.5%82.5%Alcohol, Ethyl0.78910%0.08%1%10% Flow=
1.576.3%84.0%84.0%Alcohol, Methyl0.79120%0.64%4%20% Flow=
277.8%84.0%84.0%Brine1.230%2.16%9%30% Flow=
380.3%86.5%87.5%Aviation Gasoline0.7240%5.12%16%40% Flow=
583.6%87.5%87.5%Cement Slurry1.4450%10.00%42.0%25.0%50% Flow=
7.584.6%88.5%89.5%Crude Oil0.8560%17.28%49.0%36.0%60% Flow=
1085.9%89.5%89.5%Diesel Fuel0.8470%27.44%58.0%49.0%70% Flow=
1586.8%91.0%91.0%Gasoline0.7480%40.96%67.5%64.0%80% Flow=
2088.4%91.0%91.0%Hydraulic Fluid0.8690%58.32%77.0%81.0%90% Flow=
2589.4%91.7%92.4%Jet Fuel, JP-40.78100%100.00%87.5%100%100% Flow =
3090.0%92.4%92.4%Water1.0
4090.4%93.0%93.0%Sea Water1.03Wound Rotor Motor
5091.3%93.6%93.0%% FlowAffinity HpEfficiency% MAX GPM Pres.%Eff selected control method000
6091.1%93.6%93.6%V = rpm * (D/229)0%0%0% Flow=
7591.3%94.1%94.1%PSI = (H * Sp Gr)/2.3110%0.08%1%10% Flow=
10091.6%94.1%94.5%20%0.64%4%20% Flow=
12591.6%94.5%94.5%30%2.16%9%30% Flow=
15092.2%95.0%95.0%40%5.12%16%40% Flow=
20093.5%95.0%95.0%50%10.00%44.0%25.0%50% Flow=
25095.0%95.4%60%17.28%51.5%36.0%60% Flow=
30095.0%95.4%70%27.44%60.0%49.0%70% Flow=
35095.4%80%40.96%68.0%64.0%80% Flow=
40095.8%90%58.32%79.0%81.0%90% Flow=
450100%100.00%89.0%100%100% Flow=
500
600Variable Voltage Fixed Frequency
700% FlowAffinity HpEfficiency% MAX GPM Pres.% of Rated SpeedEfficiency Static DCEfficiency VVIEfficiency Other PWMEfficiency Hydraulic
8000%0%10%
100010%0.08%1%20%
20%0.64%4%30%
30%2.16%9%40%
40%5.12%16%50%71.0%67.5%52.0%37.0%
Drive % Eff% Flow50%10.00%39.0%25.0%60%78.0%76.5%63.5%46.5%
98.5100%60%17.28%45.0%36.0%70%82.5%80.0%74.0%56.0%
98.2595%70%27.44%53.0%49.0%80%84.0%82.0%80.0%66.0%
9890%80%40.96%63.5%64.0%90%86.0%83.0%83.0%76.0%
97.7685%90%58.32%75.0%81.0%100%87.5%85.0%85.0%85.0%
97.580%100%100.00%87.0%100%
97.275%
96.9270%Throttle Valve
96.6865%% FlowAffinity HpEfficiency% MAX GPM Pres.
96.4260%0%125%
96.255%10%0.08%123%
95.950%20%0.64%120%
94.545%30%2.16%118%
93.1740%40%5.12%115%
91.835%50%10.00%39.0%112.5%
90.1530%60%17.28%45.0%110.0%
88.725%70%27.44%53.0%107.5%
80.2620%80%40.96%63.5%105.0%
90%58.32%75.0%102.5%
100%100.00%87.0%100%
AB Drive
% FlowAffinity HpEfficiency% MAX GPM Pressure
0%0%
10%0.08%1%
20%0.64%4%
30%2.16%9%
40%5.12%16%
50%10.00%25.0%
60%17.28%36.0%
70%27.44%49.0%
80%40.96%64.0%
90%58.32%81.0%
100%100.00%100%
Rockwell Automation:Click to return to "Advanced Calculator" data entry form.
Rockwell Automation:Click to return to "Advanced Calculator" data entry form.
Return
Return
Basic CalculatorFlow (Rated/Min)Linearized efficiency table for flow rates selected with Throttled system (Min Flow / Rated Flow)
Return0.200Decimal95%90%85%80%75%70%65%60%55%50%45%40%35%30%25%20%
Pump DataValueUnitsThrottling Valve20.00%0000000000000001
Rated Flow100%% Flow% FLOWWHPBHPPump Eff% HeadTotal HeadPump Eff% Flow
Minimum Flow20%100%100%73.00100.0073.0100100.073.00.00.00.00.00.00.00.00.00.00.00.00.00.00.00.073.0100%
Static Head10%95%95%69.8899.9769.9102102.069.90.00.00.00.00.00.00.00.00.00.00.00.00.00.00.069.995%
% Pressure @ Zero Flow120%90%90%66.7699.6666.8104103.866.80.00.00.00.00.00.00.00.00.00.00.00.00.00.066.890%
Pump Efficiency85%85%63.6599.0763.6106105.663.60.00.00.00.00.00.00.00.00.00.00.00.00.063.685%
@ Rated Flow73%80%80%60.5398.2360.5107.2107.260.50.00.00.00.00.00.00.00.00.00.00.00.060.580%
@ Minimum Flow20%75%75%57.4197.1557.4108.8108.857.40.00.00.00.00.00.00.00.00.00.00.057.475%
Specific Gravity1in Hg70%70%54.2995.8554.3110.2110.254.30.00.00.00.00.00.00.00.00.00.054.370%
Annual Operating Time8760Hours65%65%51.1894.3351.2111.6111.651.20.00.00.00.00.00.00.00.00.051.265%
Cost per kilowatt Hour10.5Cents60%60%48.0692.6248.1112.8112.848.10.00.00.00.00.00.00.00.048.160%
Motor DataUnits55%55%44.9490.7344.9114.0114.044.90.00.00.00.00.00.00.044.955%
Rated Power100HP50%50%41.8288.6841.8115.0115.041.80.00.00.00.00.00.041.850%
Base Speed3600RPM45%45%38.7186.4738.7116.0116.038.70.00.00.00.00.038.745%
Efficiency86.8%40%40%35.5984.1335.6116.8116.835.60.00.00.00.035.640%
35%35%32.4781.6732.5117.6117.632.50.00.00.032.535%
Flow Rate as% TimeHead30%30%29.3579.1129.4118.2118.229.40.00.029.430%
Percent of ratedat Flow(%)25%25%26.2476.4526.2118.8118.826.2026.225%
20%611920%20%20.0076.8420.0119.2119.220.02020%
25%6119
30%6118
35%6118Power requirements for different control methods
40%6117Throttled
45%6116% FlowBHPMotor EffInput HPkWhoursAnnual $
50%6115100%100.0086.80115.2185.94350.4$3,162.08
55%611495%99.9786.80115.1785.92525.6$4,741.70
60%611390%99.6686.80114.8185.65525.6$4,726.77
65%611285%99.0786.80114.1485.15525.6$4,699.03
70%611080%98.2386.80113.1784.42525.6$4,659.19
75%6109View Report75%97.1586.80111.9283.50525.6$4,607.97
80%610770%95.8586.80110.4282.37525.6$4,546.08
85%6106Summary65%94.3386.80108.6881.07525.6$4,474.23
90%6104Control MethodAnnual $60%92.6286.80106.7179.60525.6$4,393.13
95%6102Throttling Valve$71,508.3755%90.7386.80104.5377.98525.6$4,303.49
100%4100VFD Control$27,887.9250%88.6886.80102.1676.21525.6$4,206.03
Total100%Savings with VFD$43,620.4545%86.4786.8099.6274.32525.6$4,101.45
40%84.1386.8096.9372.31525.6$3,990.47
35%81.6786.8094.0970.19525.6$3,873.79
30%79.1186.8091.1467.99525.6$3,752.14
25%76.4586.8088.0865.71525.6$3,626.22
20%76.8486.8088.5366.04525.6$3,644.61
TOTAL$71,508.37
Variable Speed
% FlowBHPEffInput HPkWhoursAnnual $Motor EffDrive EffEff Factor
100%100.0085.498116.9687.25350.4$3,210.2386.898.51
95%86.6685.162094467101.7675.92525.6$4,189.6286.678976556898.250.998606
90%74.6184.826706656587.9665.62525.6$3,621.1686.5578639352980.997210
85%63.7784.4738294475.4956.32525.6$3,108.0486.409497.760.9955
80%54.0884.1222264.2947.96525.6$2,646.7386.279297.50.994
75%45.4783.741983404454.3040.50525.6$2,235.3986.15430391497.20.992561
70%37.8783.164993419245.5433.97525.6$1,874.7385.80787696.920.98857
65%31.2282.62589910437.7828.18525.6$1,555.4285.4632896.680.9846
60%25.4482.052604286831.0023.13525.6$1,276.4685.09915496.420.980405
55%20.4781.4516357225.1418.75525.6$1,034.8684.6690696.20.97545
50%16.2580.852770237320.1014.99525.6$827.4584.30945801695.90.971307
45%12.7078.88784929216.1012.01525.6$662.8683.479205694.50.961742
40%9.7677.000642780612.689.46525.6$521.8482.64531893.170.952135
35%7.3674.9014569.827.33525.6$404.4881.59291.80.94
30%5.4372.7640784787.465.57525.6$307.2380.71445290.150.92989
25%3.9170.85518131255.514.11525.6$226.9779.881827860888.70.920298
20%2.7260.7121074754.483.34525.6$184.4575.644290480.260.871478
TOTAL$27,887.92
System Curve Calculation
Flow Rate asPump CurveSys CurveSys Curve (%)Pump Curve
% of rated% HeadAff. Lawsw/ Static Head% Head (flat)
0%120010.020120.00
0.055%119.95010.219119
0.110%119.80110.918118
0.1515%119.55212.017117
0.220%119.20413.616116
0.2525%118.75615.615115
0.330%118.20918.114114
0.3535%117.551221.013113
0.440%116.801624.412112
0.4545%115.952028.211111
Static Head0.550%115.002532.510110
This is simply the elevation change from the source to the destination.0.5555%113.953037.29109
The elevation change must be converted to a percentage value.0.660%112.803642.48108
Example:0.6565%111.554248.07107
If a system has 100ft of head pressure at rated flow, and the liquid0.770%110.204954.16106
being pumped is raised 10ft, the value is 10%.0.7575%108.755660.65105
0.880%107.206467.64104
BACK0.8585%105.557275.03103
0.990%103.808182.92102
0.9595%101.959091.21101
100%100100100.00100.00
Specific Gravity
MaterialSp. Gr.
Acetone0.79
Alcohol, Ethyl0.789
Alcohol, Methyl0.791
Brine1.2
Aviation Gasoline0.72
Cement Slurry1.44
Crude Oil0.85
Diesel Fuel0.84
Gasoline0.74
Hydraulic Fluid0.86
Jet Fuel, JP-40.78
Water1.0
Sea Water1.03
Rockwell Automation:Enter a value from 20 - 100. This is a percentage of Rated Flow and represents the lowest flow rate for the application.
Rockwell Automation:Enter a value from 0 - 100. For more information click this cell for a description.
Rockwell Automation:Enter a value of 100 or greater.
Rockwell Automation:Click here for report
Rockwell Automation:Click to return to "Start"
System Curve
Pump Curve
% FLOW
% HEAD
Centrifugal Pump Energy Savings ReportRETURN
Pump DataValueUnits
Rated Flow100%
Minimum Flow20%
Static Head10%
% Pressure @ Zero Flow120%
Pump Efficiency
@ Rated Flow71%
@ Minimum Flow40%
Specific Gravity1in Hg
Annual Operating Time8760Hours
Cost per kilowatt Hour7Cents
Motor Data
Rated Power250HP
Base Speed3600RPM
Efficiency86.8%
Flow Profile
Flow Rate as% Time atHeadThrottling Valve ControlVFD Control
Percent of ratedFlow%% FlowPump BHPMotor EffMotor HPMotor kWHoursAnnual $Pump BHPEfficiencyMotor HPMotor kWHoursAnnual $
100%4100100%100.0086.80115.2185.94350.403162.08100.0085.50116.9687.25350.403210.23
95%6101.9595%99.9786.80115.1785.92525.604741.7086.6685.16101.7675.92525.604189.62
90%6103.890%99.6686.80114.8185.65525.604726.7774.6184.8387.9665.62525.603621.16
85%6105.5585%99.0786.80114.1485.15525.604699.0363.7784.4775.4956.32525.603108.04
80%6107.280%98.2386.80113.1784.42525.604659.1954.0884.1264.2947.96525.602646.73
75%6108.7575%97.1586.80111.9283.50525.604607.9745.4783.7454.3040.50525.602235.39
70%6110.270%95.8586.80110.4282.37525.604546.0837.8783.1645.5433.97525.601874.73
65%6111.5565%94.3386.80108.6881.07525.604474.2331.2282.6337.7828.18525.601555.42
60%6112.860%92.6286.80106.7179.60525.604393.1325.4482.0531.0023.13525.601276.46
55%6113.9555%90.7386.80104.5377.98525.604303.4920.4781.4525.1418.75525.601034.86
50%611550%88.6886.80102.1676.21525.604206.0316.2580.8520.1014.99525.60827.45
45%6115.9545%86.4786.8099.6274.32525.604101.4512.7078.8916.1012.01525.60662.86
40%6116.840%84.1386.8096.9372.31525.603990.479.7677.0012.689.46525.60521.84
35%6117.5535%81.6786.8094.0970.19525.603873.797.3674.909.827.33525.60404.48
30%6118.230%79.1186.8091.1467.99525.603752.145.4372.767.465.57525.60307.23
25%6118.7525%76.4586.8088.0865.71525.603626.223.9170.865.514.11525.60226.97
20%6119.220%76.8486.8088.5366.04525.603644.612.7260.714.483.34525.60184.45
Total$71,508.37Total$27,887.92
Savings per Year$43,620.45$ US
Date:1/15/02By:your name here
Customer:customer nameProject:project name/numberPump:pump name/number
Page 1 of 1
Rockwell Automation:Click to go back to previous location.
Rockwell Automation:Enter the efficiency of the pump when operated at the rated flow rate.5-30HP typical 45-72%40-150HP typical 55-75%200HP & Up typical 75-90%
Rockwell Automation:Enter the efficiency of the pump when operated at the minimum flow rate.5-30HP typical 25-55%40-150HP typical 30-60%200HP & Up typical 55-80%
Rockwell Automation:To look up the specific gravity of different liquids, click this cell. The Specific Gravity of Water is 1.0
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VFD
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Input Power (kW)
VFD vs Throttling Valve Control
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Reading a Pump Curve
Return
A pump curve shows the operating charcateristics of the pump.When the speed of the pump is varied with an AC Drive, the pump curve changes. By slowing the pump speed, head pressure is reduced, so the energy demand of the pump is reduced.
The size of the pump is shown here. This pump has a 2" outlet, a 3" inlet, and a 6" impeller (2x3-6).A set of formulas known as "Affinity Laws" based on the pump characteristics apply to centrifugal pumps operated at variable speed.
Locate the Impeller Diameter for the specific pump. The Flow (GPM) vs Head (ft) curve for that impeller size is shown in black.
The pump, with a 6.0625" impeller, will produce 325 GPM and develop ~130ft of head pressure.Where: Q = Flow (GPM) N = Pump Speed (RPM) P = Head (ft) HP = Horsepower
The efficiency of the pump at this operating point is 71%, as shown by the purple lines.Using the same example, reducing flow to 1/2 by reducing the impeller speed results in the following power requirements.
The power required to operate at this point is known as the "Brake HP". The operating point falls on the 15HP line.
In order to reduce the flow with a throttling valve, the Head increases along the pump curve since the rpm of the pump will remain constant.
The power requirements are calculated as follows:The efficiency of the drive and motor at lower speeds and loads must be taken into consideration.
Water HP = Flow x (Head/3960)Example:
Brake HP = Water HP/Pump Efficiency1.875HP
Efficiencies at 50% flow
Reducing flow by half with a throttling valve.Motor: 86%
Flow = 162.5 GPMDrive: 95.9%
Head = 153 ft1.875 / (.86 * .959) = 2.27 BHP
Water HP = 6.28 HP
Brake HP = 10.46HP
Rockwell Automation:Click here to return.
Rockwell Automation:Click to Return to "START".
Return
MBD000F2DFD.unknown
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Pump Type and Applications
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HVAC Systems
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The purpose of an HVAC (heating, ventilating, and air-conditioning) system is to provide and maintain environmental conditions within an area called the "conditioned space."
The commercial system selected for a particular application should endeavor to provide the optimum environment for employee comfort and productivity, process function, and good indoor air quality with energy efficiency and cost-savings
HVAC Systems
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Air Handling SystemsAir Handling Units (AHU), Rooftop Units (RTU), Makeup Air Units (MUA), Exhaust Fans (EF), Variable Air Volume Boxes (VAV),,fan unit (FU)
Hydronic SystemsChilled Water (CHW) [Chillers and Pumping Packages]Condenser Water (CW) [Cooling Towers]Hot Water (HW) - [Boilers and Pumping Packages]
Building Automation System (BAS)HVAC Controls, Direct Digital Controls (DDC), Energy Management System (EMS), Facility Management System (FMS)
Types of HVAC Systems
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HVAC Motor Control (Starters or VFDs)Typical Commercial HVAC Systems
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Supply fan will be controlled by PF400Controllers measure Static Pressure and send speed signals to both VFDsVAV boxes located in each room distribute conditioned airReturn fan will be controlled by PF400
Traditional Variable Air Volume (VAV) Air Handling Unit
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These motors are controlled by a Variable Frequency DriveVariable Frequency drives Replace the wasteful Check valve systemChilled Water Pumping System
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Valves replaced when drives are usedMotors controlled by VFDs in new applicationsCondenser Water Pump System
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Building Automation Systems (BAS)> Controllers Send Output Commands to VFDs and Motor Starters: Start/Stop Control & Speed Commands> Run/Fault Commands Sends Status Commands for Starter Device to Controllers.
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A pressure sensor within an air duct or pipe measures the system pressureAs the pressure changes an analog signal is sent to the BASThe BAS sends a start stop and speed command to variable frequency drives (VFDs) or motor startersWhen valves and dampers close, the pressure rises in the ducts or pipes, which reduces the speedBasic BAS Systems Control Strategies
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This is a typical view on a building automation computer screen showing the status of various points in an air handling systemBuilding Automation System Graphic
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Motor Starting Methods
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Full Voltage Starting
Reduced Voltage StartingWye - Delta StartersAutotransformer Soft Starters
Variable Frequency DrivesTypes of HVAC Motor Starting Methods
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Full Voltage StartingFull Voltage Starting CharacteristicsContacts close immediately supplying full line voltage to motor.Advantages:Lowest starter costSimple starter designsEasy to maintain and troubleshootDisadvantages:Inrush Current6-10 times rated running currentIssue when peak demand charges are enforced by utilitiesInitial Torque Mechanically hard on systemReduced life of belts, gears
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NEMA RatedServiceabilityContacts Replaceable Flexible Overload Selection
Emphasis on:
IEC RatedEmphasis on:
ReplacementContacts only replaceable on large sizes onlyConserve panel spaceClass 10 Overload Protection
IEC & NEMA Motor Starters
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Use SCRs to ramp voltage supplied to motor over a user defined time periodAdvantages: Reduces inrush current Reduces starting torque Reduces mechanical stress on motor & loads Solid State Soft Starters
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Reducing the VoltageReduces the CurrentReduction In Torque!!Soft Starter Speed Torque Curve
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Manual Starters
Range Overview1HP, 115, 230, 277 VAC 0.75 HP, 115/230 VDC1 or 2 PoleThermal Overload
Ideal for small Fan and Pump Applications
Commercial OEM Products
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Adjustable Speed Drives
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Variable Frequency Drives BasicsBenefitsSolid state technologyWide control optionsSmall size power unitsGood efficiencyLower cost, smaller motorsRetrofit existing motorsBypass capabilitySolid State AC Variable Frequency = Variable Speed
Base VoltageBase FrequencyV/Hz460607.67230603.83208603.47
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To improve process control though speed and torque controlTo improve system efficienciesTo extend life of equipment by reducing mechanical stressTo Achieve Energy Savings on Fan and Pump ApplicationsTo meet the ASHRAE Energy Standards 90.1 -2001Variable flow control on fan & pump systemsWhy Should I consider using a Variable Frequency Drive (VFD)?
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Allen Bradley PF400 HVAC DriveIntegral RS485 CommunicationsSupports DSI AccessoriesIntegral LCD KeypadOptimized for Commercial Fan and Pump ApplicationsStand-AloneApplication Specific Features for Fans and PumpsRated for Variable Torque LoadsPackaged
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PF400 RatingsRatings200-240V, 2.2-37 kW (3-50 Hp)380-480V, 2.2-100 kW (3-150 Hp)110% Overload for 60 secondsEnclosureIP20 / UL Open3-10 HP (240V AC) & 3-20 HP (480V AC)IP30 / NEMA 1 / UL Type 13-10 HP (240V AC) & 3-20 HP (480V AC) (with optional kit)15-50 HP (240V AC) & 25-150 HP (480V AC)EnvironmentIP20 rated for 50 CIP30 rated for 45 C
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Main Input Disconnect3 Contactor Full Feature Bypass with Disconnect3 Contactor Basic Bypass with DisconnectAllen Bradley PF400 HVAC DrivesStandard VFD
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Configurable Keypad with local remote start/stop and speed controlsCompatible with Building Automation System Inputs/Outputs (Start/Stop, Speed and Feedback)Standard BAS Communications: RS485, Modbus RTU, Johnson Controls N2 & Siemens P1Future Communications: Lonworks & BacnetProcess PIInertia Ride ThroughPower LossFlying StartS Curve, Accel & Decel profilesV/Hz ControlMotor Overload protectionCommunication interfaces to Building Automation SystemsAnalog & Digital inputs & outputsManual Bypass CapabilitiesPurge Start Input and FrequencyFire/Freeze Stat Interlock Inputs
Variable Frequency Drive Control CapabilitiesAnalog Output Dip SwitchesAnalog Input Dip Switches24V DC Source/Sink Relay OutputsAnalog and Discrete WiringRS485 Ports
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Motor Characteristics with Different Starting Methods
Starting Method% Voltage at Motor Terminals% Motor Starting Current% Line Current% Motor Starting TorqueLock Rotor CurrentFull Load CurrentLock Rotor CurrentFull Load CurrentLock Rotor CurrentFull Load CurrentFull Voltage100100600100600100100Autotrans.80 % tap8080480644806411565 % tap656539042390427650 % tap5050300253002545Part Winding10065390653904581Star - Delta10033198331983360Solid State 0-1000-1000-6000-1000-6000-1000-180Variable Frequency Drive0-1000-1000-2000-1000-2000-1000-180
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HVAC Motor Control Price ComparisonStandard Features: 480 VAC, 3-Phase NEMA 1 Enclosure Input Disconnect SwitchMotor Thermal Overload Protection
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ENERGY SAVINGS WITH VFDs
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Centrifugal Pump Energy SavingsThere are two methods used to accomplish the continuously varying flow:
One method is throttling which changes the system curve by use of control or throttling valve.
The other method is to vary the speed of the pump which modifies the pump curve.
Building Automation System controls the pump starter or VFD and control valve based on HVAC sequence of operation.
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Typical Pump CurvesPump Curves Throttled with Control ValvesPump Curves Controlled by a VFDEnergy Savings with VFDs (GPM Proportional Brake HP-Torque)Centrifugal Pump Energy Savings
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Many air handling systems require operation at a wide variety of points. There are several methods used to modulate or vary the flow (or CFM) of a system to achieve the optimum points. These include:
Cycling As done in home heating systems. This produces erratic airflow and is unacceptable for commercial or industrial uses.
Outlet Dampers Control louvers or dampers are installed at the outlet of the fan. To control airflow, they are turned to restrict the outlet, which reduces the airflow.
Variable Inlet Vanes by modifying the physical characteristics of the air inlet, the fans operating curve is modified which changes the airflow.
Variable Frequency Drives By changing the actual fan speed, the performance of the fan changes producing a different airflow.
Typical Fan CurvesFan Energy SavingsBuilding Automation System controls the fan starter, control dampers and air system sensors based on HVAC sequence of operation.
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Fan Curves with Outlet DampersFan Curves with Variable Inlet VanesFan Curves with VFDFan Energy Savings
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Energy Savings Software(www.sydist.com)
Energy Savings ReportVFD SpecsEnergy Savings CalculationsEnergy Savings Summary
Sample Fan Energy Savings Report
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VFD Energy Savings Software Tools
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Schaedler Yesco Distribution
HVAC Market
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Plan & Spec MarketNew Construction, Additions and RenovationsTrack projects online through Harrisburg Builders ExchangeMechanical plans/spec takeoffs for motor control thats furnished by the HVAC contractorApplication coordination with mechanical equipment specs, building automation system sequences of operations and electrical power system plans
Retrofit MarketProvided electrical energy solutions/products to Design/Build and Energy Service Teams i.e.: Variable Frequency Drives and Lighting Retrofit SolutionsVFD Fan or Pump Energy Savings Reports www.sydist.comVFD Replacement Program
Schaedler Yesco Distribution - HVAC Market
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Local Central PA Support with (5) Staffed Motor Control Specialist
Product Guide Specifications & Submittal Packages
Certified VFD Startup VFD Checklist and Reports
Onsite Training
Available Spare Parts
24/7 Emergency Service
Online Allen-Bradley Drives Technical Supportwww.ab.com/support/abdrives
Motor Control Support
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Questions ?
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Please Take a Few Minutes to Fill Out Seminar Evaluation Form
THANK YOU
Concerns about energy costs and new federal energy legislation have changed the way buildings are being built. Gone are inlet guide vanes and discharge dampers! Energy Hogs. In are VAV systems with VFDs.Secondary pumps in a primary/secondary chilled water pumping system are used to distribute the chilled water from the primary production to the loads. A primary/secondary pumping system allows constant flow to be maintained in the primary loop, while meeting the variable flow requirements of the secondary loop
Here you can see the 2 external chiller loops. The chilled water loop and the condenser water loop.Traditional NEMA products have always placed emphasis on maintainability i.e., extending useful product life cycles with an emphasis on serviceability of the device.
NEMA devices traditionally have featured replaceable contacts to extend product Application life where as the IEC device contacts are typically replaceable only on the larger ampere sizes.
With the IEC goal of compactness and low cost, it became more cost effective in the smaller sizes, to simply throw away or, replace the complete device than to extend its useful life. The smaller footprint of the typical IEC contactor for the same horsepower rating conserves panel space as well.Review of the basic design concept for reduced voltage starting.Solid state AC drives are the most recent technology.
In a solid state AC drive we take the incoming power and put it through a solid state device (diode, SCR) which converts it to DC power. Then in order to vary the speed of the motor, frequency must be changed so we take the DC bus and in effect we create a pulsed frequency signal to the AC motor through a switching device (BJT, IGBT) called an inverter. This type of technology is far more complex than DC technology, but with the advent of large scale integration has similar reliability characteristics.
Benefits of solid state AC include the use of AC motors, which are more rugged and less maintenance intensive than AC, retrofit capability, bypass capability, on a wide range of control options.
The AC drive will be more expensive than the equivalent horsepowered DC drive (but the AC motor will be less expensive than the equivalent horsepower DC motor so that an AC system drive and motor should be competitive with a DC drive and motor in most instances), low speed cogging may occur and one must take into account various installation concerns (reflected wave, common mode noise and capacitive coupling.
Sensorless Vector Control - excellent torque at all speeds.Process PI Control - Used to maintain a set level.Auto-Economizer - Used to reduce operating cost of a lightly loaded motor.Communications - Large selection of communication options available.Flying Start - Used to start the drive into a rotating motor.Speed Sensitive Electronic Motor Overload - Class 10 motor overload protection.Slip Compensation / Droop - The feature used to compensate for slip in the motor.S Curve Accel / Decel Profiles - Used to soften Accel and Decel in changes of speed.