Hvac

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

AC MOTOR LOADS

Constant Torque

Variable Torque

Constant HorsepowerAC Motor Load Types

Constant Torque Motor Loads

Variable Torque Motor Loads

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

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

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: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



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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US Dollars

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 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




Page 1 of 1

Rockwell Automation:Click to return to "Start".



Rockwell Automation:Pump Efficiency - based on "Pump Efficiency Selection" list.



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: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)


Quick Calculator

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US Dollars


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

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Pump Size 2 x 3 - 10Return

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Select the drawing below and copy it - then click Return.


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Pump Size 1.5 x 3 - 10

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Pump Size 1.5 x 3 - 13

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Rockwell Automation:Click here to return

Rockwell Automation:Click to return to "Known Pump" data entry sheet.

















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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%


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




Page 1 of 1


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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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

Pump Type and Applications

HVAC Systems

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

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

HVAC Motor Control (Starters or VFDs)Typical Commercial HVAC Systems

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

These motors are controlled by a Variable Frequency DriveVariable Frequency drives Replace the wasteful Check valve systemChilled Water Pumping System

Valves replaced when drives are usedMotors controlled by VFDs in new applicationsCondenser Water Pump System

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.

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

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

Motor Starting Methods

Full Voltage Starting

Reduced Voltage StartingWye - Delta StartersAutotransformer Soft Starters

Variable Frequency DrivesTypes of HVAC Motor Starting Methods

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

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

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

Reducing the VoltageReduces the CurrentReduction In Torque!!Soft Starter Speed Torque Curve

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

Adjustable Speed Drives

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

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)?

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

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

Main Input Disconnect3 Contactor Full Feature Bypass with Disconnect3 Contactor Basic Bypass with DisconnectAllen Bradley PF400 HVAC DrivesStandard VFD

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

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

HVAC Motor Control Price ComparisonStandard Features: 480 VAC, 3-Phase NEMA 1 Enclosure Input Disconnect SwitchMotor Thermal Overload Protection

ENERGY SAVINGS WITH VFDs

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.

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

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.

Fan Curves with Outlet DampersFan Curves with Variable Inlet VanesFan Curves with VFDFan Energy Savings

Energy Savings Software(www.sydist.com)

Energy Savings ReportVFD SpecsEnergy Savings CalculationsEnergy Savings Summary

Sample Fan Energy Savings Report

VFD Energy Savings Software Tools

Schaedler Yesco Distribution

HVAC Market

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

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

Questions ?

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.

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