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fan and pump motors waste over 30% of

power consumed
index
How is energy wasted? 3

What are the fundamental principles of energy saving using inverter drives? 4

How is energy saved when using centrifugal pumps? 4

How is energy saved when using fans? 6

Is a 30% energy saving too good to be true? 7

How does energy saving using inverters work in practice? 8

How does Control Techniques deliver energy savings? 9

How does the Government support energy savings? 10

How do I move forward with a savings plan for my pumps and fans 12

who is Control Techniques?

Control Techniques is a global no compromise specialist in variable speed drives and drive systems,
providing best practice in applications through an international network of local drive centres, from
a UK manufacturing and development centre.

Control Techniques has concentrated its skills on drive design, manufacture and application to
differentiate themselves from generalists, who, in their view, are unable to place and sustain such a
powerful focus upon this essential area of technological development and application.

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how is energy wasted?

Some 40% of industrial electricity consumption is utilised as the motive power for pumps and fans.
The vast majority of these motors are driven at constant speed by squirrel cage machines, and any
variation in system output is generally achieved by throttling or damping in the system.

Today With VTC and Verisave However, a substantial amount of this

energy is wasted. This is because most
fan and pump systems are oversized,
usually because of too much
contingency planning in the system
design, and then rounding up to the
Year 1 Year 2 next standard motor size.

Consequently, significant amounts of

energy are expended unnecessarily, and
the operating cost of the system is as
much as 50% more than it should be.
There are also significant indirect cost
savings available by extending motor life,
reducing maintenance time and cutting
Year 3 Year 4 Year 5
overall noise levels.

The overall savings to be made in

energy and indirect costs rely upon the
effective application of variable speed
AC inverter drives; for example, a 15%
reduction in fan or motor speed will
achieve a 40% energy saving.
Energy Payback Ongoing
Costs Costs Savings

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what are the fundamental principles of energy saving

using inverter drives?
The performance of pumps and fans is slightly different, so at this stage they are considered
separately in demonstrating the fundamental principles of how energy saving is achieved through the
effective application of variable speed inverter drive control.

how is energy saved when using centrifugal pumps?

When using a centrifugal pump, throttling the pump output increases the system impedance. Figure 1
shows how this change in system characteristics is represented as a net increase in the Total Dynamic
Head (TDH) of Xft. Energy is therefore dissipated at the rate equivalent to pumping B gallons per day
(gpd) to a height of Xft.

In Figure 2, the alternative is demonstrated, reducing the speed of the pump. In this case, the reduced
throughput of the system B gpd is achieved with a nett reduction in TDH of Yft. Therefore, by using
variable speed instead of throttling, the saving is the difference in THD of (X+Y)ft.

System
Characteristic
HEAD
Point B
X
Design Point A Point A
HEAD Y
Point C
Friction
head
TDH Pump characteristic
speed constant
Static head Pump characteristic
TDH reduced speed

0 B A 0 B A
throughput gpd Figure 1 throughput gpd Figure 2

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The combined set of typical pump characteristics is shown in Figure 3, illustrating the effect of speed
variation verses throttling on both pump efficiency and absorbed power. The most notable points
illustrated are that throttling the system does not reduce throughput at the cost of increasing
absorbed power as popularly believed; the power absorbed does reduce as the throttle is closed.

The absorbed power locus which passes through points PN1 and PN2, indicates that even at zero
flow, some power is still absorbed, and this constant component of absorbed power is necessary to
overcome the static head, which is constant in many pump systems. The power locus has a cube
law characteristic for speed/flow against power, and this enables a calculation of the energy savings.

In Figure 3, the efficiency

characteristics are also shown. The Throttled
System
pump is selected to operate at peak Unthrottled
System
efficiency, but throttling the system
Pump
Characteristics
defeats that objective, and results in at Full
Speed N1
the pump operating at an efficiency
well below its peak value. From the Pump Power
Characteristics Locus
(Reduced
efficiency curves, it is clear that from Speed
N2)
approximately 70% to 100%
ABSORBED POWER (kW)

throughput, little efficiency is lost by HEAD PN

varying the speed. 1
0 Ful Speed Power
Curve Power Saving by
Speed Variation
Consequently, it is clear that Power at Speed N2
PN
significant energy, and therefore 70
2 1
2
cost, savings are available by using a 60
Pump
Efficiency
variable speed system employing 50 Pump Efficiency at Full Speed
Efficiency Reduced N1
% Speed N2
inverter drives instead of throttling 40

the pump.
B A
0 FLOW GPD Figure 3

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how is energy saved when using fans?

In a similar way to the pump illustration, Figure 4 Outlet Damper Control
demonstrates the performance of a fan alongside a
Fan
characteristic showing the system resistance. Where the two Pressure
P1
curves intersect, the fan performance meets the system
Pressure
requirements. Should a variation in volume be required, it is P

necessary to achieve control by damping the system or

System Fan
varying the fan motor speed. Pressure Performance
P2
ce
tan
si s
Outlet damping control is similar to throttling a pump. Figure Re
te m
S ys
V2 V1
4 demonstrates where a reduced volume V2 is required, a
Volume Figure 4
pressure drop P must be effected across an outlet damper, in
order to meet the system requirement, which at V2 is less Inlet Damper Control
Dam
p er
Op
than the capability of the fan. Thus energy is wasted, usually as Da
m
pe
en
rP

ta n c e
m
heat and noise.

S yste
ar
ti a

R e sis
ll y
Op

Pressure
en

In Figure 7, graph A shows how absorbed power varies as

the system is damped. Taking this example to the extreme, if
Fan &
the damper were completely closed, a considerable amount P System
Pressure
of energy would be wasted in simply pressurising the system.

By placing inlet dampers directly in the input to the fan,

Volume Figure 5
vortices are generated in the airflow, reducing the efficiency of
the fan as illustrated in Figure 5. This is less wasteful of energy Variable Speed Control
than outlet damping as demonstrated by graph B in Figure 7, Fu
ll S
pe
ed
as energy is not dissipated in pressurising the system. Inlet
damping is also less noisy which is important in air
ce
R e ste m
ta n
sis
Sy

conditioning, heating and ventilation systems. Red

uc
ed
Sp
Pressure
ee

The results achieved by varying the speed of the fan using an

d

inverter are demonstrated in Figure 6. In Figure 7, an P Fan & System

illustration of how power absorbed in this method of control

varies in comparison to inlet and output
Volume Figure 6
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damper control. As graph C intersects with both A and
B, it indicates that when the fan is required to operate at
full capacity, or close to it, the inverter losses exceed
damping losses, and are additional in the system. The
A gradients of the relevant graphs indicate how rapidly
pe
r
B energy savings can be achieved as throughput is reduced.
am
tD
tle r
Ou pe
trol

Power am C
tD Fans are similar to pumps in their operation
Con

I nl e
eed

characteristics; however, unlike pumps, fans can be

Sp
le
ia b

controlled by damping of the input in addition to

r
Va

throttling of the fan output.

0 50 100
% of Design Volume Figure 7

is a 30% energy saving too good to be true?

No. By expertly assessing the pump or fan control system, and making appropriate measurements,
the true cost saving will appear, and this example illustrates a typical situation.

The first step in deciding if an inverter would be cost effective is to calculate the payback period in
years, which is based upon the total project capital cost divided by the expected annual saving.

Example: Pump Application

A 22kW centrifugal pump running continuously at 50% flow.
Comparison of operating costs between pump throttling and Control Techniques VTC inverter
control, using typical losses at 50% flow:
- kW needed for throttle system = 55% of 22kW = 12.1kW
- kW needed for inverter system = 25% of 22kW = 5.5kW
- Savings = 6.6kW More than 50%!

If the pump operates on a duty cycle of 12 hours per day, 7 days per week, for 48 weeks per year,
the annual saving is considerable.
- 6.6kW x 12 x 7 x 48 = 26,611 kWh
Assuming a cost of electricity at 0.05/kWh, the annual savings are 26,611 kWh x 0.05 = 1,330!
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how does energy saving using inverters work in practice?
These are examples from the Control Techniques portfolio of case studies demonstrating the proven
energy cost savings achieved by effective application of Control Techniques VTC inverter drives to fan
and pump control.

Chiller Pump Running Costs Reduced By Over 1,000 Per Month

Site: DVLA Swansea.
Contractor: Planned Maintenance Regional Services.
Product: Control Techniques 160kW Unidrive VTC inverter drive system.
Project: Reduce the power requirement of the chiller water circulating pump.
Options: Change the motor or introduce an inverter drive system to replace the pump star/delta starter
Decision: Inverter drive system based upon Control Techniques 160kW Unidrive VTC System.
Result: Power consumption down from almost 160kW to 50kW, saving between 100kWh and 115kWh for
12-15 hours per day, providing a payback within 18 months of installation.
Summary: Control Techniques delivered, installed and commissioned the main and standby drives systems in only
16 hours. The Control Techniques inverter drive selected was the 160kW Unidrive VTC, which has been
designed to meet the special needs of the HVAC market, including features dynamic voltage/ frequency
control which automatically optimises the voltage to the required load. The consequence is an additional
energy efficiency as the motor flux is matched to the actual need.

39% of Energy Costs Saved!

Site: Oxford Brookes University Students Union.
Product: Control Techniques Unidrive VTC inverter drive system.
Project: Reduce the power requirement of the air handling system which uses two 25kW two-speed motors for
extraction and supply of fresh air to the union. Energy consumption of the supply and return fans over their
duty cycles showed an annual return of around 164,000kWh.
Original Control System:
Star/Delta starters and manual switching between full speed, at 25kW and low speed at 7kW Control
improvements were necessary to provide an appropriate response to the number of people using the union facility.
New Control System:
Control Techniques Unidrive VTC system, providing a continuous adjustment to fan speed.
Result: A considerably improved level of temperature and air quality control, plus a reduction in power
consumption of approximately 60,000kWh per year. This will provide an annual saving of 2,500 and
payback in just over 2.5 years at current energy costs.
Summary: The Control Techniques VTC Unidrive system matched the motor speed to the requirements of the air handling
system, resulting in a substantial energy saving, which was very close to the original theoretical calculations.

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how can Control Techniques deliver energy savings?
Initially a Control Techniques specialist will if requested conduct an on-site fan and pump energy survey.
Alternatively, it is a simple matter for the user to conduct his own survey and calculate the anticipated
savings using Windows based CTSAVE software, available free on request.

% Heating Pump Cooling Pump

110
100
90
Flow rate %
80
70 Energy used %
60
%
50 50
40 40
30 30
20 20
10 10
0 Hour Hour
0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8

Most fan and pump systems are over-sized for anything less than full flow. Consequently a significant
amount of energy is wasted and the operating costs are unnecessarily high. The Control Techniques
CTSAVE software system illustrates the real potential savings, including a payback calculation which is
worked out by dividing the project capital cost using the Control Techniques Unidrive VTC Inverter
System by the expected annual savings.

0700 CONTROL (0700 2668765) for more product information or FREE CTSAVE software.

900
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what Government legislation forces energy saving?

In 2001, UK business is going to be hit with a savage increase in electricity costs, currently
estimated at 25%. This is being levied by HM Government, through the Climate Change Levy,
to stimulate the carbon reduction commitments made at Kyoto in 1997. This will motivate many
businesses to survey their fan and pump installations, then fit speed control where appropriate
and move towards a cleaner environment. Frequently, fan and pump systems are larger,
sometimes far larger, than necessary. This results from designers choosing to err on the positive
side, as an undersized system cannot easily be made larger, whilst an over-large system can be
turned down. Clearly this situation will have to change in the very near future.

how does the Government support energy savings?

Control Techniques VTC inverter drive products are recognised under the Energy
Saving Trust [EST] Energy Efficiency branding scheme. Please contact Control
Techniques on 0700 CONTROL if you require more information on the
scheme, which highlights its main message in the following text.

A Message From The Energy Saving Trust

You dont have to be a genius to save money on your energy bill. Just look for products and services
where you see the Energy Efficiency logo. They save or use less energy, and save you money. And,
because they use the latest technology, theres no compromise on performance. This prestigious logo
has been introduced by the Energy Saving Trust, an independent, Government funded body, working
in partnership with industry. Look for it. Anything else is a waste of energy.

Energy Saving Trust

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Control Techniques co-operation with

SWALEC Energy Saving Partnership has successfully pioneered an innovative mechanism for the
supply of energy saving drives to industry and commerce.

an innovative way to
reduce your
costsenergy The Energy Saving Partnership has been developed
by SWALEC to enable businesses to realise energy savings without the need to invest in their capital.
Under this scheme the costs of installing energy efficient equipment are met by SWALEC and the
investment is recovered by sharing the value of the energy savings with the customer. Funding is
available for a wide range of energy efficient technology including lighting and motor control.

investing in energy
efficiency Whilst we are able to offer a wide range of
competitive energy supply prices, you do not have to buy your power from SWALEC to qualify as
an energy saving partner. We will establish the energy saving potential of your business for you, and
recommend the right technology to reduce your bills.

who pays for the installation? Under the partnership agreement

SWALEC will fund and arrange the installation of energy efficient equipment. The investment will
be recovered by sharing energy cost savings over an agreed contract period.

For more information contact Bob Oglesby at SWALEC

01222 773927
SWALEC (South Wales Electricity) Energy Services, Newport Road, Cardiff, CF3 9XW
Phone 01222 334824, Fax 01222 773980, e-mail laura.german@hyder.com
or fill in and return the reply paid card opposite.
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how do I move forward with a savings plan for my

pumps and fans?
Please make your selections from the FREE material list below, and if you require more
immediate information, please telephone

0700 CONTROL (0700 2668765)

Is your application a FAN M or a PUMP M Your Initials

What size is it? kW Your Surname

Running current (if known) amps Job Title

How many hours per day does it run? hrs Company Name

How many days per week? days Address

Application?

Current method of control

How much do you pay County

per unit for electricity? p/unit
Postcode
M please arrange a Control Techniques specialist
Telephone
to call me or my colleague below and discuss
a FREE energy savings site survey. Facsimile

E-mail

M please send me a FREE CTSAVE software

pack to calculate my own survey Many thanks for your interest in Control
Techniques energy saving variable speed drives.

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Control Techniques
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Control Techniques
UK Marketing Centre
Unit 5
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Newtown
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Tel: 01686 612900
Fax: 01686 612999

Control Techniques 2001. The information contained in this brochure is for guidance only and does not form part of any contract. The accuracy cannot be guaranteed as
Control Techniques have an ongoing process of development and reserve the right to change the specification of their products without notice.