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VFD
VFD CALCULATORS
CALCULATORS
for
for Fan
Fan &
& Pump
PumpApplications
Applications
1-800-962-3787
Special thanks to the Bonneville Power Adminstration for permitting us to distribute this tool to energy professionals worldwide,
as well as Christopher B. Milan, PE, CEM Mechanical & Civil Engineer, B.P.A. for developing these calculators.
See the complete line of energy saving drives from Cerus by clicking on the photo below:
If you have any questions regarding these tools, please click to email Chris Milan at bpa.gov
This, and other handy calculators can be found at http://www.cerusind.com/calculators.asp
Click here for extensive analysis tools at DOE web site
Comparison of Inlet and Outlet Dampers
104.4 102.93
100.0 100.00
89.6
62.8
60.0 60.00 59.75
51.1
43.46
40.0 40.7 40.00
32.0
30.38
25.0
20.0 20.0 20.00 20.27
16.4 17.0
12.89
8.00
4.75 5.37
0.0 0.00
0 20 40 60 80 100 120 0 20 40 60 80 100 120
% of Design CFM % of Design CFM or % of Full Speed RPM
The power curves above are used in the energy savings analysis. Curves developed from data obtained by measuring the operating characteristics of
various fan systems and from information provided in "Flow Control", a Westinghouse publication, Bulletin B-851, F/86/Rev-CMS 8121. Curves are
representative, not precise,
final economic analysis should be based on actual power (kW) measurements of the fan system.
Facility Information
Sample Duty Cycles (these can be used as a guide if the duty cycle is not known)
Sample Duty Cycle - HIGH FAN LOADING Sample Duty Cycle - LOW FAN LOADING
70 60
55
Percent of Time at this Capacity
60
60
50
Percent of Time at this Capacity
50
40
40
30
25
30
20 20 20
20 15
10
10
5
0 0
50 75 Capacity (cfm) 90 30 50Design Capacity
Percent of 70 (cfm) 90
Percent of Design
Summary
This calculator was developed by Chris Milan at the Bonneville Power Administration (BPA) and is intended to be used as an estimation of potential energy savings and simple payback for
ASD installations. Final economic decisions should be based upon more extensive analysis tools than what is provided here.
If you have any questions or comments, please email Chris Milan at the following: cbmilan@bpa.gov
More extensive analysis tools are available at the following DOE web site: http://www.eere.energy.gov/industry
* This is an Excel 2000 file and is approximately 2.5 MB in size.
(FC) Forward-Curved Fans (BI) Backward-Inclined Fans Radial-Blade Fans Axial Fans
ampers
The fan blades curve in the direction of rotation. The fan blades tilt back, away from the direction These fans are typically the most rugged of all This fan group includes Propeller, Tubeaxial, and
Descriptions and Fan Efficiencies
These fans are typically not as large as other fan of rotation. The main difference between fans in types and can range from Paddle-Wheel design Vaneaxial fans. The fan blades are installed
types and structurally are not very rugged. Fan this category is the shape and construction of to Flat Blades with corrosion resistance coatings. perpendicular to the air stream. The majority of
efficiencies are in the range of 55 to 65%. the blades. The Backward-Inclined Flat blades These fans usually operate at lower volumes but these fans can be operated in reverse which
tend to be more rugged and allow some higher pressures than other fan types. The wide allow them to supply or exhaust the air.
particulate to pass through but these blades are openings between the blades allow larger Propeller fans generate high airflows but
not very aerodynamic and therefore are the least material to pass through and also minimizes minimum pressure and are the least expensive
efficient. The Backward-Inclined Curved blades vibrations when operating during conditions and least efficient. To increase the pressure and
are more efficient but their orientation with the when the flow and pressure drops. The efficiency these fans are placed inside a hollow
air stream can allow moisture and particulate to construction of these fans allows them to be tube to form the Tubeaxial fan. To further
collect on the blades which reduces fan modified to meet specific applications and to be increase the efficiency and develop a more
performance and may cause excessive repaired at minimum costs. Typical ranges of fan unified air stream, outlet vanes are installed to
vibrations. The efficiency ranges from 75 to efficiencies for Flat Blades is 55 to 65% and 60 form the Vaneaxial fan.
85%. The Backward-Inclined Airfoil blade to 75% for the Radial Tip.
resembles the wing of an aircraft and is the most
efficient fan type with efficiencies over 90%.
The typical performance curve for a Forward The fan performance curve for Backward The performance curve for fans with Radial The fan performance curve for this group of fans
Curved fan contains a dip in the static pressure Inclined fans is similar to the forward curve but Blade wheels is typically a smooth curve showing indicates that they are capable of providing high
Performance Characteristics
curve to the left of the point of maximum static typically has a smaller dip in the static pressure the pressure steadily dropping from a maximum flow rates at lower pressures than other fan
pressure. This region of the performance curve curve. The major difference of the backward at zero flow to a minimum pressure at full flow. types. These fans will typically have a unique
indicates that the characteristics of the air flow inclined fans is the characteristics of the BHP This characteristic allows stable operation of the BHP curve that requires maximum power at zero
through the fan was not consistent. As the flow curve. The horsepower curve does not increase fan throughout a wide range of flow(cfm) by flow rate. The horsepower and static pressure
increases, the static pressure increases and to a maximum amount at maximum flow rate but adjusting the pressure. The corresponding BHP will increase and decrease as flow increases
decreases within this region. It is not instead will reach a peak and then drop off as curve increases at a linear rate as the fan flow until finally reaching a minimum value at
recommended to operate the fan within this the flow rate continues to increase to it's rate increases. The Radial Tip fan performance maximum flow rate. These variations in flow and
unstable region of the fan curve due to the maximum amount. This characteristic allows the curve is a blend of the Backward- Inclined and pressure result in different flow rates at the same
unpredictable flow characteristics. This area is designer to select a motor size for the worst Radial Blade curves. The BHP curve increases operating pressure, causing instability and
sometimes referred to as the "stall" region. case(design) conditions and if any errors or to a maximum amount at maximum flow. The control problems. Operating within this region
changes occur that would increase the flow Radial Tip is more efficient than the Radial Blade should be avoided.
requirements, the fan will not be overloaded. and therefore requires less horsepower to
This is typically referred to as a "non- produce the same output.
overloading" power curve.
Due to the narrow openings between fan blades, As stated above, these fans are typically "non- These fans are the fans of choice for moving Propeller fans are common on cooling towers
these fans are not suited for airstreams overloading" and this characteristic makes them material or air in harsh operating environments. and inexpensive exhaust systems. Tubeaxial
containing particulate. These fans usually a popular choice for applications were the They are used to convey everything from air and Vaneaxial fans are used in HVAC exhaust
operate at low volumes and low speeds such as system performance is uncertain at maximum filled with particulate to wood chips, rock or metal applications were higher pressures and flow
in residential HVAC units. flow rates. The inside of these blades are scrap rates are required. All of these fans produce
usually hollow to reduce their weight but the significant airflow noise when compared to other
Applications
Reference: "Improving Fan System Performance" Industrial Technologies and Best Practices Web Site at: http://www.oit.doe.gov
104.0
80.0 81.4
84.6
40.0
0.0
0 20 40 60 80 100 120
% of Design CFM
20.0
Inlet Damper Box, General Curve
120.0
0.0
106.7 0 20 40 60 CFM
% of Design 80 100 120
100.0
91.9
% of Design Input Power (kW)
80.0 81.2
73.9
64.0
66.0
69.1 These power curves are used in the energy savings
60.0 56.1
59.8
62.2
analysis. Curves developed from data obtained by
50.3 measuring the operating characteristics of various
fan systems and from information provided in "Flow
40.0
Control", a Westinghouse publication, Bulletin B-851,
F/86/Rev-CMS 8121. Curves are representative, not
20.0 precise. Final economic analysis should be based on
actual power(kW) measurements of the fan system.
0.0
0 20 40 60 80 100 120
% of Design CFM
Page 8 of 16 Bonneville Power Administration Revision No. 1
Outlet Damper Graphs
Outlet Damper Control, Outlet Damper Control, Radial Blade,
Forward Curve Fans Backward Inclined & Airfoil Fans
120.0 120.0
d Outlet Dampers
110.0
105.9
105.2
102.1
100.0 100.0
96.3
90.6
90.0 88.7
% of Design Input Power (kW)
71.5
70.0
64.6
63.6
60.0 60.0
57.2
53.8 53.3
52.6
50.0
44.5
40.0 40.0
36.7
30.4 30.0
25.6
22.3
20.0 20.4 20.0
10.0
0.0 0.0
0 20 40 60 80 100 120 0 20 40 60 80 100 120
% of Design CFM % of Design CFM
The power curves above are used in the energy savings analysis. Curves developed from data obtained by measuring the operating characteristics of various fan
systems and from information provided in "Flow Control", a Westinghouse publication, Bulletin B-851, F/86/Rev-CMS 8121. Curves are representative, not
precise, final economic analysis should be based on actual power(kW) measurements of the fan system.
Sample Duty Cycles (use these as a guide if the duty cycle is not known)
Sample Duty Cycle - HIGH FAN LOADING Sample Duty Cycle - LOW FAN LOADING
70 60
55
60
60 50
Percent of Time at this Capacity
Percent of Time at this Capacity
50
40
40
30
25
30
20 20 20
20 15
10
10 5
0 0
50 Percent of Design
75Capacity (cfm) 90 30 50Design Capacity
Percent of 70 (cfm) 90
Summary
This calculator was developed by Chris Milan at the Bonneville Power Administration (BPA) and is intended to be used as an indication of the potential energy savings and
simple payback for ASD installations. If you have any questions or suggestions for improvements, please contact Chris Milan at cbmilan@bpa.gov. More extensive analysis
tools are available at: http://www.eere.energy.gov/industry.
Inlet Guide Vanes are installed across the opening of the fan inlet. Outlet dampers do not change the characteristics of the entering Adjustable Speed Drives(ASDs) control the flowrate by
By opening and closing, they vary the amount of air entering the airstream. Outlet dampers control flowrate by restricting the electronically adjusting the speed of the motor driving the fan or
fan and change the profile of the entering airstream. As the air amount of air being discharged. This restriction allows the air flow pump. Similar to Inlet Guide Vanes, as the speed is reduced, the
passes through the vanes it begins to swirl in the same rotation as rate to be varied the same way a discharge throttle valve adjusts flowrate, pressure and horsepower requirement is reduced which
the fan impeller, this pre-spinning of the air reduces the the volume of flow out of a pump. The resistance of flow through results in a new performance curve for each speed setting. With
momentum that the fan blades can impact on the entering air and the system increases as the flow(cfm) of air increases. This ASDs, as speed is reduced the horsepower requirement is
therefore reduces the velocity and pressure of the discharged air. relationship is shown graphically by plotting the flow and decreased according to the affinity laws within a squared to cubic
As the vanes continue to close, this swirling action increases and corresponding resistance(pressure) to generate the system relationship depending upon the amount of static pressure and how
continues to decrease the pressure and flow the fan delivers to resistance curve. When the system curve and fan performance the system responds to changes in flow and pressure. A system
the system. The fan horsepower is proportional to the flow and curve are shown on the same graph, the intersection of these two containing static head and in which small increases in flow result in
pressure, therefore the horsepower requirement also decreases. curves defines a unique point of operation. When the fan is large pressure drops will have a system curve that rises steeply.
Because the inlet vane opening affects all three of these fan installed in this particular system and operates at this flow rate, it By plotting this system curve and a system curve that does not rise
characteristics, a new fan performance curve is created whenever will produce this pressure. The fan can only operate as shown by steeply onto the same fan or pump performance curves at various
the vane position is changed. Inlet control does not affect the it's performance curve, for a given pressure it will provide a unique speeds, one can see the following relationship. That for the same
Characteristics
system curve, as vane positions change the fan performance flow or vice versa. reduction in flow rate, the system curve that rises steeply will
curve rides up and down the system curve. require more speed reductions to obtain this reduced flow and
Operating
Inlet dampers can be oriented to provide the same affect as inlet With outlet damper control, any new operating point is achieved In determining the appropriate application of an ASD, the entire
guide vanes but usually are not as effective at inducing the by adjusting the characteristics of the system curve, not the fan system should be evaluated. For example, if the fan or pump and
appropriate swirl. The blades typically operate in parallel with performance curve. For example, in order to reduce the fan flow electric motor is oversized, further reductions in operating speed
each other. If the inlet dampers are installed too far from the fan rate, as the outlet dampers begin to close, the system's could result in significant reductions in motor efficiency as well as
inlet or are not oriented properly, they only serve to restrict the resistance(pressure) increases and shifts the system curve the efficiencies of the fan, pump. In some cases the motor can be
entering airflow. upward until it intersects the fan performance curve to define a re-sheaved to confirm energy savings and system response to
new operating point of increased pressure and reduced flow. reduced speeds prior to purchasing the drive.
Inlet Dampers are usually a better choice of flow control than Dampers are an efficient method of fully open/closed flow control ASDs are an excellent choice of flow control if the system allows
Outlet Dampers because when properly installed, they allow the such as exhaust air or outside air intakes. Outlet dampers are the the fan or pump to operate at reduced flow rates and loads for a
fan horsepower to be reduced as the flow is reduced. Inlet Guide least efficient method of variable flow control. In order for the fan significant portion of the operating time. The ASDs provide quick
Vanes usually provide more accurate control of fan performance to compensate for this increase in system pressure when the and accurate adjustments to flow rate and pressure as required to
than Inlet Dampers. Inlet Guide Vanes are an efficient method dampers begin to close, it has to move to the left up along the maintain set point. Another advantage of ASD control is their soft
for controlling flow rates down to approximately 70% of capacity. performance curve to the higher operating pressure. For the starting capabilities which reduces the high in-rush currents at
This would correspond to a vane position of approximately 50% majority of fans, as you continue to restrict flow and increase start-up. Operating at reduced speeds can increase the equipment
Disadvantages
Advantages/
closed. If the desired fan flow rate requires that the vanes be pressure, the fan operates in the least efficient and unstable life, reduce vibrations and noise. For fan applications were the flow
closed more than 50%, adjustable speed drives usually provide region of the fan performance curve. Operating at higher system rate does not vary significantly, inlet guide vanes may be a better
more efficient controllability by reducing the fan speed rather than pressures than necessary to reduce the flow rate not only wastes choice of control. ASDs are not 100% efficient, therefore operating
continuing to restrict the fan inlet with the guide vanes. energy but increases the air leakage throughout the system. the motor at full speed with the ASD will increase the input power
Depending upon the variation in flow rates required by the due to the inefficiency of the drive. ASDs typically require that they
system, inlet guide vanes or adjustable speed drives may provide be placed in a clean, conditioned environment which could result in
more energy efficient flow control. high installation costs.
Inlet Dampers are usually a better choice of flow control than Dampers are an efficient method of fully open/closed flow control ASDs are an excellent choice of flow control if the system allows
Outlet Dampers because when properly installed, they allow the such as exhaust air or outside air intakes. Outlet dampers are the the fan or pump to operate at reduced flow rates and loads for a
fan horsepower to be reduced as the flow is reduced. Inlet Guide least efficient method of variable flow control. In order for the fan significant portion of the operating time. The ASDs provide quick
Vanes usually provide more accurate control of fan performance to compensate for this increase in system pressure when the and accurate adjustments to flow rate and pressure as required to
than Inlet Dampers. Inlet Guide Vanes are an efficient method dampers begin to close, it has to move to the left up along the maintain set point. Another advantage of ASD control is their soft
for controlling flow rates down to approximately 70% of capacity. performance curve to the higher operating pressure. For the starting capabilities which reduces the high in-rush currents at
This would correspond to a vane position of approximately 50% majority of fans, as you continue to restrict flow and increase start-up. Operating at reduced speeds can increase the equipment
Disadvantages
Advantages/
closed. If the desired fan flow rate requires that the vanes be pressure, the fan operates in the least efficient and unstable life, reduce vibrations and noise. For fan applications were the flow
closed more than 50%, adjustable speed drives usually provide region of the fan performance curve. Operating at higher system rate does not vary significantly, inlet guide vanes may be a better
more efficient controllability by reducing the fan speed rather than pressures than necessary to reduce the flow rate not only wastes choice of control. ASDs are not 100% efficient, therefore operating
continuing to restrict the fan inlet with the guide vanes. energy but increases the air leakage throughout the system. the motor at full speed with the ASD will increase the input power
Depending upon the variation in flow rates required by the due to the inefficiency of the drive. ASDs typically require that they
Inlet Guide Vanes and system, inlet guide vanes or adjustable
Outlet speed drives may provide be placed in a clean, conditioned environment which could result in
Adjustable
more energy efficient flow control. high installation costs.
Inlet Dampers Dampers Speed-Drives
Reference: "Improving Fan System Performance" Industrial Technologies and Best Practices Web Site at: http://www.oit.doe.gov
Eddy Current Drive Pump Flow Control ASD Pump Flow Control
120.00 120.00
Outlet Dampers
104.45
100.00 100.00
102.79
% of Design Input Power (kW)
62.77
60.00 60.00 59.53
51.06
43.19
40.00 40.75
40.00
32.01
30.37
25.03
20.00 16.40 17.04
19.98 20.00 21.07
14.32 13.05 15.30
0.00 0.00
0 20 40 60 80 100 120 10 20 30 40 50 60 70 80 90 100 110
% of Design Flow (gpm) % of Design Flow (gpm) or % of Full Speed(rpm)
0
Page 13 of0 16 20 100Bonneville
120 Power Administration Revision No. 1
%40
of Design60Flow (gpm)
80
53.72
% of Design In
43.12
40
33.38
Pump Drives Power Graphs
24.92
20 18.16
13.51
0
0 20 %40
of Design60Flow (gpm)
80 100 120
Values used in spreadsheet
Facility Information
P ercen t o f T im e at th is C ap acity
Sample Duty Cycles (these can be used as a guide if the duty cycle is not known)
Sample Duty Cycle - HIGH PUMP LOADING Sample Duty Cycle - LOW PUMP LOADING
70 60
55
60
60 50
50
40
40
30
25
30
20 20 20
20 15
10 10
5
0 0
50 75 Capacity (gpm)
Percent of Design 90 30 50of Design Capacity (gpm)
Percent 70 90
Summary
This calculator was developed by Chris Milan at the Bonneville Power Administration (BPA) and is intended to be used as an estimation of potential energy savings and simple
payback for ASD installations. Final economic decisions should be based upon more extensive analysis tools than what is provided here.
If you have any questions or comments, please email Chris Milan at the following: cbmilan@bpa.gov
% of Design (kW)
Constant Recirculation, Bypass Control 125 Throttling Valve Flow Control
105
et and Outlet Dampers
78
95 75 73
67
90 50
85 25
80 0
10 20 30 40 50 60 70 80 90 100 110 10 20 30 40
% of Design Flow (gpm) % of 50 60
Design 70
Flow 80
(gpm) 90 100 110
The power curves above are used in the energy savings analysis. Curves developed from data obtained by measuring the operating characteristics
of various pumps and from information provided in "Flow Control", a Westinghouse publication, Bulliten B-851, F/86/Rev-CMS 8121. Curves are
representative, not precise, final economic analysis should be based on actual power (kW) measurements of the pumping system.