Energy Savings Calculator - Pump and Fan VFD Retrofit

Introduction

This calculator is designed to provide savings estimates for VFD fan and pump installations. The tool can be used in conjunctio
with generic load profiles and estimated full load motor loading.
This tool has three specific calculation pages:
1) VFD Fan Analysis - fan applications
2) VFD Pump Analysis - Pump applications where system flow will vary throughout the year
3) Throttle Valve Analysis - Pump applications where system flow will remain constant and a VFD is being used to replace a th

Fan Analysis Instructions

Step 1
Step 2
Step 3

Step 4
Step 5

Step 6

Enter fan motor information (motor hp and efficiency from motor nameplate or other documented source)
Estimate motor load factor, or use default load factor (80%).
Determine fan motor full load kW - the analysis will be based on a calculated value determined from Step 1, or th
If Full Load (100% flow) spot Power measurements have been taken enter the value in
If Full Load (100% flow) spot Amperage measurements are available, estimate full load
Enter the fan's annual hours of operation
Select existing and proposed control systems
The control type selection determines which standard part load performance curve will b
The curves were developed from data obtained by measuring the operating characterist
https://save-energy-now.org/EM/tools/Documents/pumps/VSD%20Calculator%20for%2
Select annual load profile
If annual load profile is known from site metered data or site specific schedules
If annual load profile is not known, select a generic load profile in cell B25 which repres

Savings Calculation Method

The results of the analysis are presented in the table and graphs to the right of the input section. The savings val
Annual hours of operation (column M) for each of the pump load bins is determined by m
The existing (column N) and proposed (column Q) full load power percentage is taken fr
The existing (column O) and proposed (column R) pump power is determined by multip
The existing (column P) and proposed (column S) annual energy usage (kWh) is determ
The total annual energy savings is the sum of difference between the annual energy usa
Pump Analysis Instructions
Step 1
Step 2
Step 3

Step 4
Step 5

Step 6

Enter pump motor information (motor hp and efficiency from motor nameplate or other documented source)
Estimate motor load factor, or use default load factor (80%).
Determine pump motor full load kW - the analysis will be based on a calculated value determined from Step 1, or
If Full Load (100% flow) spot Power measurements have been taken enter the value in
If Full Load (100% flow) spot Amperage measurements are available, estimate full load
Enter the pump's annual hours of operation
Select existing and proposed control systems
The control type selection determines which standard part load performance curve will b
The curves were developed from data obtained by measuring the operating characteris
Select annual load profile
If annual load profile is known from site metered data or site specific schedules
If annual load profile is not known, select a generic load profile in cell B25 which best r

Savings Calculation Method

The results of the analysis are presented in the table and graphs to the right of the input section. The savings val
Annual hours of operation (column M) for each of the pump load bins is determined by m

The existing (column N) and proposed (column Q) full load power percentage is taken fr
The existing (column O) and proposed (column R) pump power is determined by multip
The existing (column P) and proposed (column S) annual energy usage (kWh) is determ
The total annual energy savings is the sum of difference between the annual energy usa
Throttle Valve Instructions
Step 1
Step 2
Step 3

Enter pump motor information (motor hp and efficiency from motor nameplate or other documented source)
Estimate motor load factor, or use default load factor (80%).
Determine pump motor power - the analysis will be based on a calculated value determined from Step 1, or the u
If Full Load (100% flow) spot Power measurements have been taken enter the value in
If Full Load (100% flow) spot Amperage measurements are available, estimate full load
If no full load spot measurements are available, estimate motor load factor in cell F6
Step 4
Enter the pump's annual hours of operation
Step 5
Determine existing system flow:
If the system flow is known from site metered data or spot measurements
If only the existing valve position is known select "Known Valve Position" in cell E22 and
Savings Calculation Method
The results of the analysis are presented in the table to the right of the input section. The savings values present
The existing system power is determined from the measured value, or calculated based
The throttling devise moves the system curve to the left and the pump's power is reduce
Calculated from either the value in cell F26 if "Know Existing
System % Flow
Existing System - Full Load Power
Calculated from throttle valve regression curve from "Pump C
Proposed System - Full Load Power
Calculated from VSD regression curve from "Pump Curves"
The total annual energy savings is the sum of difference between the annual energy usage of the existing and pr

Retrofit

The tool can be used in conjunction with site specific spot measurements and logged data of

a VFD is being used to replace a throttling valve (e.g., triple-duty valve)

other documented source)

alue determined from Step 1, or the user may input full load kW based on field measurements:
have been taken enter the value in cell F8
nts are available, estimate full load kW using calculation method in cells C46:F46 and standard power factor table. Enter estimated kW calc

part load performance curve will be used in the calculations. All part load curves were taken from the Bonneville Power Administration publ
easuring the operating characteristics of various pumps and from information provided in "Flow Control", a Westinghouse publication, Bullet
mps/VSD%20Calculator%20for%20Pumps%20Tip%20Sheet.pdf

ta or site specific schedules select "custom or metered" in cell B25. Enter annual load profile in cells D29:D39
oad profile in cell B25 which represents the expected annual load profile

the input section. The savings values presented are calculated as follows:
pump load bins is determined by multiplying the load profile % by the total annual hours of operation
l load power percentage is taken from the fan load curves located on the "Fan Curves" worksheet
mp power is determined by multiplying the full load pump power( cell F7 or F8) by the corresponding full load power percentage
nual energy usage (kWh) is determined by multiplying the associated full load power by the total annual hours in that bin
nce between the annual energy usage of the existing and proposed usage (cell P23 - cell S23)

or other documented source)

d value determined from Step 1, or the user may input full load kW based on field measurements:
have been taken enter the value in cell F8
nts are available, estimate full load kW using calculation method in cells C46:F46 and standard power factor table. Enter estimated kW calc

part load performance curve will be used in the calculations. All part load curves were taken from the Bonneville Power Administration publ
easuring the operating characteristics of various pumps and from information provided in "Flow Control", a Westinghouse publication, Bulle

ta or site specific schedules select "custom or metered" in cell B25. Enter annual load profile in cells D29:D39
oad profile in cell B25 which best represents the expected annual load profile the pump will serve

the input section. The savings values presented are calculated as follows:
pump load bins is determined by multiplying the load profile % by the total annual hours of operation

l load power percentage is taken from the fan load curves located on the "Fan Curves" worksheet
mp power is determined by multiplying the full load pump power( cell F7 or F8) by the corresponding full load power percentage
nual energy usage (kWh) is determined by multiplying the associated full load power by the total annual hours in that bin
nce between the annual energy usage of the existing and proposed usage (cell P23 - cell S23)

or other documented source)

ue determined from Step 1, or the user may input motor power based on field measurements:
have been taken enter the value in cell F8
nts are available, estimate full load kW using calculation method in cells C46:F46 and standard power factor table. Enter estimated kW calc
ate motor load factor in cell F6

or spot measurements select "Known Existing Capacity" in cell E22 and enter the flow as a percentage of the full load GPM in cell F26
own Valve Position" in cell E22 and enter the valve percent open position in cell F26

ection. The savings values presented are calculated as follows:

easured value, or calculated based on the percent load reduction caused by using a throttling devise
eft and the pump's power is reduced (known as riding the pump curve)
value in cell F26 if "Know Existing Capacity" is selected or calculated from a standard throttle position curve contained on the "Throttling va
lve regression curve from "Pump Curves" worksheet and the system % flow
ession curve from "Pump Curves" worksheet and the system % flow
nergy usage of the existing and proposed usage (cell P12 - cell S12)

ble. Enter estimated kW calculated in cell B46 into cell F8

e Power Administration published documents

tinghouse publication, Bulletin B-851, F/86/Rev-CMS 8121.

ower percentage

ble. Enter estimated kW calculated in cell B46 into cell F8

e Power Administration published documents

stinghouse publication, Bulletin B-851, F/86/Rev-CMS 8121.

ower percentage

ble. Enter estimated kW calculated in cell B46 into cell F8

full load GPM in cell F26

ntained on the "Throttling valve curves" worksheet if "Know valve position" is selected

Fan Motor Information

Enter nameplate horsepower:
Enter nameplate efficiency:
Enter motor load factor:
Calculated full load power:
Or, Enter motor power, if measured:

10.00
91.00%
80.00%
6.56

hp
percent
percent (default 80%)
kW
overridescalculated
calculatedpower;
power leave
- leaveblank
blankif ifu
kW (overrides

Operating Parameters
4,000

Enter hours per year fan operates:

hrs/yr

Fan Control Method Selection

Select existing control type:

Constant Volume

Select proposed control type:

VSD

Load Curve Selection

Look up table reference #
2

Select load curve profile

HVAC fan
HVAC fan
% flow
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Total

User Input
% time at
Capacity

% time at
Capacity

0%
0%
0%
0%
0%
10%
20%
30%
20%
15%
5%
100%

0%
0%
0%
0%
10%
15%
15%
20%
15%
15%
10%
100%

Analysis Profile
0%
0%
0%
0%
0%
10%
20%
30%
20%
15%
5%

Savings Analy

Annual energy savings, kWh

Percent savings
EFLH of proposed system

13,086
49.8%
1,994

ulated power - leave blank if unknown

Part load performance
% flow req'd
Op hrs
0%
0

Look up table reference #

9

10%

20%

30%

40%

50%
2

60%

70%
80%

Existing system
Full load power
100%

100%
100%

100%
100%

400

100%

800

100%

1,200

100%

800

100%

90%

600

100%

100%

200

100%

Total

4,000

Load P
35%
30%
25%
20%
% Time at Capacity

15%
10%
5%
0%

0%

10%

20%

30%

% Flow (percen

Savings Analysis Results

Existing system
kW
6.56

kWh
0

Proposed system
Full load power
kW
5%
0.31

kWh
0

6.56

5%

0.31

6.56

5%

0.35

Savings
kWh
0

0
0

6.56

8%

0.53

6.56

13%

0.85

2,094

6.56

2,626

20%

1.33

532

6.56

5,252

30%

1.99

1,595

6.56

7,877

43%

3,656

3,423

4,454

3.92

3,138

2,114

6.56

3,939

80%

5.22

3,131

807

6.56

1,313

103%

6.76

1,351

-38

13,171

13,086

6.56

5,252

2.85

60%

26,258

Load Profile

20%

30%

40%

50%

60%

70%

% Flow (percent of full flow required to meet load)

80%

90%

100%

Pump Motor Information

Enter nameplate horsepower:
Enter nameplate efficiency:
Enter motor load factor:
Calculated full load power:
Or, Enter motor power, if measured:

100.00
95.0%
80.0%
62.88
60.00

hp
percent
percent (default 80%)
kW
overridescalculated
calculatedpower;
power leave
- leaveblank
blankif ifu
kW (overrides

Operating Parameters
Enter hours per year pump operates:

4,000

hrs/yr

Pump Control Method Selection

Select existing control type:

None-Constant Volume

Select proposed control type:

VSD

Load Curve Selection

Look up table reference #
6

Select load curve profile

Custom or Metered
Custom or Metered
% flow
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Total

User Input

% time at
Capacity
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%

% time at
Capacity
0%
0%
0%
0%
10%
15%
15%
20%
15%
15%
10%
100%

Analysis Profile
0%
0%
0%
0%
10%
15%
15%
20%
15%
15%
10%

ulated power - leave blank if unknown

Look up table reference #

5
2

Savings Analysis Results

Annual energy savings, kWh

Percent savings
EFLH of proposed system

122,393
51.0%
1,946

Part load performance

% flow req'd
Op hrs
0%
0

Existing system
Full load power
kW
100%
60.00

10%

100%

60.00

20%

100%

60.00

kWh
0

0
0

30%

100%

60.00

40%

400

100%

60.00

24,000

50%

600

100%

60.00

60%

600

100%

60.00

70%
80%

800

100%

600

60.00

100%

60.00

36,000
36,000

48,000
36,000

90%

600

100%

60.00

36,000

100%

400

100%

60.00

24,000

Total

4,000

240,000

Load Profile
35%
30%
25%
20%
% Time at Capacity

15%
10%
5%
0%

0%

10%

20%

30%

40%

50%

60%

70%

% Flow (percent of full flow required to meet load

s Results

Proposed system
Full load power
kW
27%
16.47

kWh
0

19%

11.47

14%

8.59

Savings
kWh
0

0
0

13%

7.83

15%

9.18

3,672

20,328

21%

12.64

7,586

28,414

30%

18.22

10,932

43%

25.91

20,730

25,068

27,270

35.72

21,432

14,568

79%

47.64

28,585

7,415

103%

61.68

24,671

-671

117,607

122,393

60%

ofile

40%

50%

60%

70%

of full flow required to meet load)

80%

90%

100%

Pump Motor Information

Enter nameplate horsepower:
Enter nameplate efficiency:
Enter motor load factor:
Calculated motor power:
Or, Enter motor power, if measured:

100.00
95.0%
80.0%
62.88

hp
percent
percent (default 80%)
kW
overridescalculated
calculatedpower;
power leave
- leaveblan
bla
kW (overrides

Operating Parameters
4,000

Enter hours per year pump operates:

hrs/yr

Pump Control Method Selection

Select existing control type:

Throttle Valve

Select proposed control type:

VSD
Existing Flow Determination

Select flow calculation method:

Enter existing valve position (percent open):

Enter existing flow capacity:

Estimating power (kW) from measured amps:
kW
amps
volts
ph
5.74
8.0
460
3
Estimating power (kW) from rated full load amps:
kW
FLA
volts
ph
5.74
10.0
460
3

HP
0.001
0.250
0.330
0.500
0.750
1.0
1.5
2.0
3.0
5.0
7.5
10
15

Known Valve Position

50.00

80.00

% of full load GP

power factor
0.90
power factor
0.90

Motor Efficiency & Power Factor

Efficiency
Power Factor
Std
Prem.
Std
Prem.
50.00%
55.00%
50.00%
55.00%
62.70%
67.50%
53.33%
57.80%
66.00%
68.80%
62.42%
64.16%
69.00%
73.90%
61.68%
63.35%
76.00%
78.50%
66.00%
74.55%
82.04%
84.59%
72.50%
76.50%
83.67%
85.83%
72.90%
77.20%
83.73%
85.98%
76.90%
78.80%
86.12%
88.54%
78.10%
80.00%
86.81%
88.47%
82.20%
83.20%
88.16%
90.08%
83.10%
83.40%
89.25%
90.58%
84.00%
85.20%
90.02%
91.37%
84.70%
84.70%

load factor
0.80

20
25
30
40
50
60
75
100
125
150
200
300
350
400
450
500
9999

90.13%
91.73%
91.55%
91.86%
91.87%
92.80%
93.01%
93.19%
93.10%
93.47%
93.61%
95.30%
95.40%
95.30%
95.00%
95.20%
95.20%

91.70%
92.57%
92.57%
93.04%
93.01%
93.48%
93.50%
93.77%
93.88%
94.24%
94.40%
95.80%
95.90%
95.60%
95.00%
95.20%
95.20%

86.00%
85.90%
87.20%
86.00%
85.60%
87.30%
87.70%
87.80%
88.60%
88.80%
88.30%
90.40%
89.30%
89.40%
90.00%
90.50%
90.50%

85.50%
85.80%
86.40%
85.60%
85.90%
85.80%
86.80%
86.30%
86.80%
86.90%
86.70%
86.80%
88.80%
86.90%
90.00%
90.50%
90.50%

Savings Analy

Annual energy savings (kWh)

Percent savings

66,961
27.8%

ulated power - leave blank if unknown

Part load performance
System % Flow
Op hrs
85%
4,000
Total
4,000
Look up table reference #
6
2

Look up table reference #

1
Estimated total flow
85%

% of full load GPM

Existing system
Full load power
96%

Savings Analysis Results

Existing system
kW
60.13

kWh
240,519
240,519

Proposed system
Full load power
kW
69%
43.39

kWh
173,558
173,558

Savings
kWh
66,961
66,961

Fan System Type

VSD

Pump System Types

VSD

Eddy Current Drives

Eddy Current Drives

Inlet Guide Vane, FC Fans

Torque Converter

Inlet Guide Vane, BI & Airfoil Fans

None-Constant Volume

Inlet Damper Box

Throttle Valve

Outlet Damper, FC Fans

Outlet Damper, BI & Airfoil Fans

Constant Volume

Fan Curves

HVAC fan

3-Duty Flow Selection

Known Valve Position

Known Existing Capacity

Medium Load

Low Load

CO Garage Fan

Custom or Metered

Pump Curves

Medium Load

Low Load

Custom or Metered

% Design Pump Power (kW)

3

% Capacity (GPM)

VSD

Eddy Current

Torque Converter

0%

27.4

16.4

13.5

10%

20%
30%

40%
50%

60%
70%

80%
90%

100%

19.1

17.0

18.2

14.3

20.0

24.9

13.0

25.0

15.3

33.4

32.0

21.1

43.1

40.7

30.4

53.7

51.1

43.2

64.8

62.8

59.5

75.8

75.7

79.4

86.5

89.6

102.8

96.3

104.4

104.9

Pump Control Types

120.0
100.0
80.0
% Design Pump Power (kW)

f(x)
100.853x
+ 27.44751
f(x) =
= 176.2x^2
- 19x^2 +- 63.7x
+ 55.2124
R =
=1
R
1

60.0
40.0
20.0
0.0
0%

20%

40%

60%

% Capacity (GPM)

80%

None-Constant
Volume

Throttle Valve

100.0

55.2

100.0

61.4

100.0

67.2

100.0

72.6

100.0

77.7

100.0

82.3

100.0

86.6

100.0

90.5

100.0

94.0

100.0

97.2

100.0

99.9

rol Types

0%

y (GPM)

Eddy Current
VSD
Polynomial (VSD)
Torque Converter
None-Constant Volume
Throttle Valve
Logarithmic (Throttle Valve)
Polynomial (Throttle Valve)
80%

100%

120%

% Design Fan Power (kW)

5

% Capacity (CFM)

VSD

Eddy Current

Inlet Guide Vane

Control Forward
Curve Fans

Inlet Guide Vane

Control, BI & Airfoil
Fans

0%

4.8

10.4

20.0

47.3

10%

4.8

17.0

20.6

52.6

20%

5.4

20.0

21.6

55.8

30%

8.0

25.0

23.3

57.4

40%

12.9

32.0

26.4

58.5

50%

20.3

40.7

31.5

59.9

60%

30.4

51.1

38.9

62.3

70%

43.5

62.8

49.4

66.7

80%

59.8

75.5

63.3

73.8

90%

79.5

89.6

81.4

84.6

100%

102.9

104.4

104.0

99.8

Fan Control Typ

120.0
100.0
80.0

% Design Fan Power (kW)

60.0
40.0
20.0
0.0
0%

20%

40%

60%
% Capacity (CFM)

80

Design Fan Power (kW)

6

Inlet Damper Box

Outlet Damper Control

Forward Curve Fans

Outlet Damper Control,

Radial Blade Backward
Inclined & Airfoil Fans

Constant Volume

50.3

20.4

55.9

100.0

56.1

22.3

52.6

100.0

59.8

25.6

53.3

100.0

62.2

30.4

57.2

100.0

64.0

36.7

63.6

100.0

66.0

44.5

71.5

100.0

69.1

53.8

80.2

100.0

73.9

64.6

88.7

100.0

81.2

76.9

96.3

100.0

91.9

90.6

102.1

100.0

106.7

105.9

105.2

100.0

n Control Types
VSD
Eddy Current
Inlet Guide Vane Control Forward Curve
Fans
Inlet Guide Vane Control, BI & Airfoil Fans
Inlet Damper Box
Outlet Damper Control Forward Curve Fans
Outlet Damper Control, Radial Blade
Backward Inclined & Airfoil Fans
60%

apacity (CFM)

80%

100%

Constant Volume
120%

% Capacity
0%

HVAC fan
0%

Medium Load
0%

Low Load
5%

10%

0%

0%

10%

20%

0%

0%

10%

30%

0%

5%

10%

40%

0%

10%

20%

50%

10%

20%

10%

60%

20%

30%

10%

70%

30%

20%

10%

80%

20%

10%

10%

90%

15%

5%

5%

100%

5%

0%

0%

100%

100%

100%

5
CO Garage Sensor
60%

Custom or Metered
0%

0%

0%

0%

0%

0%

0%

0%

0%

20%

0%

10%

0%

10%

0%

0%

0%

0%

0%

0%

0%

100%

Typical valve/damper performance

% flow

Typical Throttle

% open

Typical valve

100

100

90

98

80

96

70

93

60

90

70

50

85

60

40

79

30

69

20

55

10

35

100
f(x) = - 0.000002331x^4 + 0.000663
90
R = 0.9995467579
80

% Flow

50
40
30
20
10
0
0

10

20

A
B
C

= design point, operating conditions with throttling valve partially closed

= operating conditions, throttling valve 100% open
= operating conditions, pump/fan speed reduced

ical Throttle Valve Performance Curve

0002331x^4 + 0.0006631702x^3 - 0.0726223776x^2 + 3.9524475524x + 0.5944055944

67579

10

20

30

40

50
% Open

60

70

80

90

100

partially closed