VFD CALCULATORS

for Fan & Pump 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

Page 2 of 14

Bonneville Power Administration

Revision No. 1

Comparison of Inlet and Outlet Dampers

Page 3 of 14

Bonneville Power Administration

Revision No. 1

Fan Drives Power Graphs

Eddy Current Drive Fan Flow Control

104.4

% of Design Input Power (kW)

% of Design Input Power (kW)

89.6

80.0
75.7

62.8

51.1
40.7

40.0
32.0
25.0

20.0

16.4

20.0

17.0

102.93

100.00

100.0

60.0

Adjustable Speed Drive Fan Flow Control

120.00

120.0

80.00

79.50

60.00

59.75

43.46

40.00
30.38
20.27

20.00
12.89
5.37

4.75

0.0
0

20

40

60

% of Design CFM

80

100

120

8.00

0.00
0

20

40

60

80

% of Design CFM or % of Full Speed RPM

100

120

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.

Page 4 of 14

Bonneville Power Administration

Revision No. 1

ADJUSTABLE SPEED DRIVE ENERGY SAVINGS CALCULATOR

~ Fan Applications ~

Fan Motor Information

100.00
85.00
80.00
70.21

Enter Nameplate Horsepower:

Enter Nameplate Efficiency:
Enter Motor Load at Fan Design CFM:
Power(kW) at Fan Design CFM:

hp
%
%
KW

www.cerusind.com
1-800-3543787

Facility Information
Enter Hours per year fan operates:
Enter Energy Charge:

80
0.05

hrs/yr
$/kwh

Existing Flow Control Method and Fan Type

Select Flow Control and
Fan Type Below

Click to go to the Fan Types worksheet for more information

1

1 Inlet Guide Vane, FC Fans

2 Inlet Guide Vane, BI & Airfoil Fans
3 Inlet Damper Box

Duty Cycle

Power (kW) readings to be used

in the analysis

Power Analysis

Savings Analysis

Existing System
Enter
Enter Percent of Design Percent of
Capacity (CFM)
Time at this Existing System
Percent of
Capacity
Design (KW)

0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%

7 Selection 7 allows Measured

4 Outlet Damper, FC Fans

5 Outlet Damper, BI & Airfoil Fans
6 Eddy Current Drives

5.0%
5.0%
10.0%
10.0%
10.0%
10.0%
10.0%
10.0%
10.0%
10.0%
10.0%

Totals:

Do Not
Enter Data
Below

ASD System
Percent of
Design (kW)
for ASD
System

Existing System
Power (kW)

20.00
20.64
21.57
23.32
26.44
31.45
38.92
49.36
63.33
81.37
104.01

14.04
14.49
15.14
16.37
18.56
22.08
27.32
34.66
44.47
57.13
73.03

5.90
4.75
5.37
8.00
12.89
20.27
30.38
43.46
59.75
79.50
102.93

2,584.31 Kwh/yrexisting

100.0%

Annual Energy
Savings (Kwh/yr)

ASD System Power (kW)

4.14
3.33
3.77
5.62
9.05
14.23
21.33
30.51
41.95
55.82
72.27

Annual Energy Cost

Savings ($/yr)

39.60
44.64
90.99
86.03
76.09
62.84
47.97
33.18
20.13
10.52
6.04

2,066.29 Kwh/yrasd

$
$
$
$
$
$
$
$
$
$
$

1.98
2.23
4.55
4.30
3.80
3.14
2.40
1.66
1.01
0.53
0.30

518.03 $

25.90

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

60

70

Percent of Time at this Capacity

60

Percent of Time at this Capacity

60

50
40
30
20

20

20

10
0
50

75
Percent of Design Capacity
(cfm)

55

50
40
30
20

25
15

10
0

90

5
30

50
70
Percent of Design
Capacity (cfm)

90

Summary
Energy Savings:
Cost Savings:
Enter Materials Cost:

518.03 KWH/yr
25.90
-

$
$

Enter Labor Cost:

Total Cost:
Simple Payback:

years

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:
More extensive analysis tools are available at the following DOE web site:

cbmilan@bpa.gov
http://www.eere.energy.gov/industry

* This is an Excel 2000 file and is approximately 2.5 MB in size.

Page 5 of 14

Bonneville Power Administration

Revision No. 1

Applications

Performance Characteristics

Descriptions and Fan Efficiencies

Common Fan Types

(FC) Forward-Curved Fans

(BI) Backward-Inclined Fans

Radial-Blade Fans

Axial Fans

The fan blades curve in the direction of rotation. These fans

are typically not as large as other fan types and structurally
are not very rugged. Fan efficiencies are in the range of 55 to
65%.

The fan blades tilt back, away from the direction of rotation.
The main difference between fans in this category is the
shape and construction of the blades. The Backward-Inclined
Flat blades tend to be more rugged and allow some
particulate to pass through but these blades are not very
aerodynamic and therefore are the least efficient. The
Backward-Inclined Curved blades are more efficient but their
orientation with the air stream can allow moisture and
particulate to collect on the blades which reduces fan
performance and may cause excessive vibrations. The
efficiency ranges from 75 to 85%. The Backward-Inclined
Airfoil blade resembles the wing of an aircraft and is the most
efficient fan type with efficiencies over 90%.

These fans are typically the most rugged of all types and can
range from Paddle-Wheel design to Flat Blades with corrosion
resistance coatings. These fans usually operate at lower
volumes but higher pressures than other fan types. The wide
openings between the blades allow larger material to pass
through and also minimizes vibrations when operating during
conditions when the flow and pressure drops. The
construction of these fans allows them to be modified to meet
specific applications and to be repaired at minimum costs.
Typical ranges of fan efficiencies for Flat Blades is 55 to 65%
and 60 to 75% for the Radial Tip.

This fan group includes Propeller, Tubeaxial, and Vaneaxial

fans. The fan blades are installed perpendicular to the air
stream. The majority of these fans can be operated in reverse
which allow them to supply or exhaust the air. Propeller fans
generate high airflows but minimum pressure and are the least
expensive and least efficient. To increase the pressure and
efficiency these fans are placed inside a hollow tube to form
the Tubeaxial fan. To further increase the efficiency and
develop a more unified air stream, outlet vanes are installed to
form the Vaneaxial fan.

The typical performance curve for a Forward Curved fan

contains a dip in the static pressure curve to the left of the
point of maximum static pressure. This region of the
performance curve indicates that the characteristics of the air
flow through the fan was not consistent. As the flow
increases, the static pressure increases and decreases within
this region. It is not recommended to operate the fan within
this unstable region of the fan curve due to the unpredictable
flow characteristics. This area is sometimes referred to as the
"stall" region.

The fan performance curve for Backward Inclined fans is

similar to the forward curve but typically has a smaller dip in
the static pressure curve. The major difference of the
backward inclined fans is the characteristics of the BHP curve.
The horsepower curve does not increase to a maximum
amount at maximum flow rate but instead will reach a peak
and then drop off as the flow rate continues to increase to it's
maximum amount. This characteristic allows the designer to
select a motor size for the worst case(design) conditions and if
any errors or changes occur that would increase the flow
requirements, the fan will not be overloaded. This is typically
referred to as a "non-overloading" power curve.

The performance curve for fans with Radial Blade wheels is

typically a smooth curve showing the pressure steadily
dropping from a maximum at zero flow to a minimum pressure
at full flow. This characteristic allows stable operation of the
fan throughout a wide range of flow(cfm) by adjusting the
pressure. The corresponding BHP curve increases at a linear
rate as the fan flow rate increases. The Radial Tip fan
performance curve is a blend of the Backward- Inclined and
Radial Blade curves. The BHP curve increases to a maximum
amount at maximum flow. The Radial Tip is more efficient than
the Radial Blade and therefore requires less horsepower to
produce the same output.

The fan performance curve for this group of fans indicates that
they are capable of providing high flow rates at lower
pressures than other fan types. These fans will typically have
a unique BHP curve that requires maximum power at zero flow
rate. The horsepower and static pressure will increase and
decrease as flow increases until finally reaching a minimum
value at maximum flow rate. These variations in flow and
pressure result in different flow rates at the same operating
pressure, causing instability and control problems. Operating
within this region should be avoided.

Due to the narrow openings between fan blades, these fans

are not suited for airstreams containing particulate. These
fans usually operate at low volumes and low speeds such as
in residential HVAC units.

As stated above, these fans are typically "non-overloading"

and this characteristic makes them a popular choice for
applications were the system performance is uncertain at
maximum flow rates. The inside of these blades are usually
hollow to reduce their weight but the build up of moisture and
particulate can lead to cavities which reduces their efficiency.
The narrow openings can limit the size of particulate in the air
stream they can tolerate. These fans are a good choice for
installations on the clean side of the process air stream for
material and dust handling systems and for forced-draft fans
in boilers.

These fans are the fans of choice for moving material or air in
harsh operating environments. They are used to convey
everything from air filled with particulate to wood chips, rock or
metal scrap

Propeller fans are common on cooling towers and inexpensive

exhaust systems. Tubeaxial and Vaneaxial fans are used in
HVAC exhaust applications were higher pressures and flow
rates are required. All of these fans produce significant airflow
noise when compared to other fans.

Reference: "Improving Fan System Performance" Industrial Technologies and Best Practices Web Site at: http://www.oit.doe.gov

Page 6 of 14

Bonneville Power Administration

Revision No. 1

power curve is over loading.go 105%

Inlet Guide Vane Control, BI & Airfoil Fans

120.0

Inlet Guide Vane Control, Forward Curve Fans

120.0

80.0

100.0

104.0

100.0

99.8

81.4

63.3

60.0
49.4

40.0

38.9
31.5
26.4

20.0

20.0

21.6

20.6

23.3

0.0
0

20

40

60

80

% of Design CFM

100

120

% of Design Input Power (kW)

% o f D e s i g n In pu t Po w e r (k W )

Inlet Vane Graphs

84.6

80.0
73.8
66.7

60.0
52.6

55.8

57.4

58.5

59.9

62.3

47.3

40.0

20.0

Inlet Damper Box, General Curve

120.0
0.0
106.7

100.0

20

40

60

% of Design CFM

80

100

120

% of Design Input Power (kW)

91.9

80.0

81.2
73.9

60.0

56.1

59.8

62.2

64.0

66.0

69.1

These power curves 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 B851, 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.

50.3

40.0
20.0
0.0

20

40

60

80

100

120

% of Design CFM

Page 7 of 14

Bonneville Power Administration

Revision No. 1

Outlet Damper Graphs

Outlet Damper Control,

Forward Curve Fans

120.0

Outlet Damper Control, Radial Blade,

Backward Inclined & Airfoil Fans
120.0
110.0

105.9

105.2

100.0

102.1

100.0
96.3

80.0

90.0

% of Design Input Power (kW)

% of Design Input Power (kW)

90.6

76.9

64.6

60.0
53.8
44.5

40.0

36.7
30.4

88.7

80.0

80.2
71.5

70.0
63.6

60.0

57.2
53.3

52.6

50.0
40.0
30.0

25.6
20.4

20.0

22.3

20.0
10.0
0.0

0.0
0

20

40

60

% of Design CFM

80

100

120

20

40

60

% of Design CFM

80

100

120

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.

Page 8 of 14

Bonneville Power Administration

Revision No. 1

ADJUSTABLE SPEED DRIVE ENERGY SAVINGS CALCULATOR

~ Fan Applications ~
Motor Information

Enter Nameplate Horsepower:

Enter Nameplate Efficiency:
Enter Motor Load at Fan Design CFM:
Power(KW) at Fan Design CFM:

50.00
95.00
90.00
35.34

Enter Hours per year fan operates:

Enter Energy Charge:

8760
0.05

hp
%
%
KW

This Sample Input Sheet is for viewing

This Sample
Input
Sheet
forinputted
viewingor
purposes
only. No
values
canisbe
purposesItonly.
No values
be inputted
changed.
is included
herecan
to give
the useror
changed.
It what
is included
here
to give
an idea of
types of
values
canthe
beuser
an idea
of either
what types
of values
can or
be
entered
into
the Fan
Calculator
entered
into
either theworksheets.
Fan Calculator or
Pump
Calculator
Facility Information
Pump Calculator worksheets.

hrs/yr
$/kwh

Flow Control Method and Fan Type

Select Flow Control and
Fan Type Below

Click to go to the Fan Types worksheet for more information

1 Inlet Guide Vane, FC Fans
2 Inlet Guide Vane, BI & Airfoil Fans
3 Inlet Damper, General Curve

4 Outlet Damper, FC Fans

5 Outlet Damper, BI & Airfoil Fans
6 Eddy Current Drives

Duty Cycle

Power Analysis

Savings Analysis

Existing System

Enter
Percent of
Design
Capacity
(CFM)

Enter Percent
of Time at
this Capacity

25.0%
50.0%
70.0%
90.0%

15.0%
55.0%
25.0%
5.0%

Totals:

7 Measured kW

Existing
System
Percent of
Design (KW)

54.90
71.53
88.71
102.08

ASD System
Annual Energy Cost
Savings ($/yr)

ASD System Power (KW)

6.42
20.27
43.46
79.50

231,719.64 Kwh/yrexisting

100.0%

Annual Energy
Savings (Kwh/Yr)

Percent of
Design (KW)
for ASD
System

Do Not
Existing
Enter Data System Power
Below
(KW)
19.40
25.28
31.35
36.07

2.27
7.16
15.36
28.09

22,511.26
87,270.91
35,022.55
3,494.89
0.00
0.00
0.00
0.00
0.00
0.00
0.00

83,420.05 Kwh/yrasd

$
$
$
$

1,125.56
4,363.55
1,751.13
174.74

148,299.60 $

7,414.98

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

50
40
30
20

20

10

Percent of Time at this Capacity

Percent of Time at this Capacity

60

20

55

60

50
40
30
20

25

15

10

0
50

75
Percent of Design Capacity
(cfm)

30

90

50
Percent of Design
Capacity (cfm)70

90

Summary
Energy Savings: (Note 1)
Cost Savings:
Enter Materials Cost:

$
$

148,299.60 KWH/yr
7,414.98
950.00

Enter Labor Cost:

Total Cost:
Simple Payback:

$
$

100,000.00
100,950.00
13.61 years

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.

Page 9 of 14

Bonneville Power Administration

[Revision No. 1]

TYPES OF AIRFLOW CONTROL

Outlet
Dampers

Adjustable
Speed-Drives

Inlet Guide Vanes are installed across the opening of the fan inlet. By opening and
closing, they vary the amount of air entering the fan and change the profile of the
entering airstream. As the air passes through the vanes it begins to swirl in the
same rotation as the fan impeller, this pre-spinning of the air reduces the momentum
that the fan blades can impact on the entering air and therefore reduces the velocity
and pressure of the discharged air. As the vanes continue to close, this swirling
action increases and continues to decrease the pressure and flow the fan delivers to
the system. The fan horsepower is proportional to the flow and pressure, therefore
the horsepower requirement also decreases. Because the inlet vane opening
affects all three of these fan characteristics, a new fan performance curve is created
whenever the vane position is changed. Inlet control does not affect the system
curve, as vane positions change the fan performance curve rides up and down the
system curve.

Outlet dampers do not change the characteristics of the entering airstream. Outlet
dampers control flowrate by restricting the amount of air being discharged. This
restriction allows the air flow rate to be varied the same way a discharge throttle
valve adjusts the volume of flow out of a pump. The resistance of flow through the
system increases as the flow(cfm) of air increases. This relationship is shown
graphically by plotting the flow and corresponding resistance(pressure) to generate
the system resistance curve. When the system curve and fan performance curve are
shown on the same graph, the intersection of these two curves defines a unique
point of operation. When the fan is installed in this particular system and operates at
this flow rate, it will produce this pressure. The fan can only operate as shown by it's
performance curve, for a given pressure it will provide a unique flow or vice versa.

Adjustable Speed Drives(ASDs) control the flowrate by electronically adjusting the

speed of the motor driving the fan or pump. Similar to Inlet Guide Vanes, as the
speed is reduced, the flowrate, pressure and horsepower requirement is reduced
which results in a new performance curve for each speed setting. With ASDs, as
speed is reduced the horsepower requirement is decreased according to the affinity
laws within a squared to cubic relationship depending upon the amount of static
pressure and how the system responds to changes in flow and pressure. A system
containing static head and in which small increases in flow result in large pressure
drops will have a system curve that rises steeply. By plotting this system curve and a
system curve that does not rise steeply onto the same fan or pump performance
curves at various speeds, one can see the following relationship. That for the same
reduction in flow rate, the system curve that rises steeply will require more speed
reductions to obtain this reduced flow and therefore the greater the opportunity for
energy savings.

Inlet dampers can be oriented to provide the same affect as inlet guide vanes but
usually are not as effective at inducing the appropriate swirl. The blades typically
operate in parallel with each other. If the inlet dampers are installed too far from the
fan inlet or are not oriented properly, they only serve to restrict the entering airflow.

With outlet damper control, any new operating point is achieved by adjusting the
characteristics of the system curve, not the fan performance curve. For example, in
order to reduce the fan flow rate, as the outlet dampers begin to close, the system's
resistance(pressure) increases and shifts the system curve upward until it intersects
the fan performance curve to define a new operating point of increased pressure
and reduced flow.

In determining the appropriate application of an ASD, the entire system should be

evaluated. For example, if the fan or pump and electric motor is oversized, further
reductions in operating speed could result in significant reductions in motor efficiency
as well as the efficiencies of the fan, pump. In some cases the motor can be resheaved to confirm energy savings and system response to reduced speeds prior to
purchasing the drive.

Inlet Dampers are usually a better choice of flow control than Outlet Dampers
because when properly installed, they allow the fan horsepower to be reduced as
the flow is reduced. Inlet Guide Vanes usually provide more accurate control of fan
performance than Inlet Dampers. Inlet Guide Vanes are an efficient method for
controlling flow rates down to approximately 70% of capacity. This would
correspond to a vane position of approximately 50% closed. If the desired fan flow
rate requires that the vanes be closed more than 50%, adjustable speed drives
usually provide more efficient controllability by reducing the fan speed rather than
continuing to restrict the fan inlet with the guide vanes.

Dampers are an efficient method of fully open/closed flow control such as exhaust
air or outside air intakes. Outlet dampers are the least efficient method of variable
flow control. In order for the fan to compensate for this increase in system pressure
when the dampers begin to close, it has to move to the left up along the
performance curve to the higher operating pressure. For the majority of fans, as you
continue to restrict flow and increase pressure, the fan operates in the least efficient
and unstable region of the fan performance curve. Operating at higher system
pressures than necessary to reduce the flow rate not only wastes energy but
increases the air leakage throughout the system. Depending upon the variation in
flow rates required by the system, inlet guide vanes or adjustable speed drives may
provide more energy efficient flow control.

ASDs are an excellent choice of flow control if the system allows the fan or pump to
operate at reduced flow rates and loads for a significant portion of the operating time.
The ASDs provide quick and accurate adjustments to flow rate and pressure as
required to maintain set point. Another advantage of ASD control is their soft starting
capabilities which reduces the high in-rush currents at start-up. Operating at reduced
speeds can increase the equipment life, reduce vibrations and noise. For fan
applications were the flow rate does not vary significantly, inlet guide vanes may be a
better choice of control. ASDs are not 100% efficient, therefore operating the motor at
full speed with the ASD will increase the input power due to the inefficiency of the
drive. ASDs typically require that they be placed in a clean, conditioned environment
which could result in high installation costs.

Advantages/
Disadvantages

Operating
Characteristics

Inlet Guide Vanes and

Inlet Dampers

Reference: "Improving Fan System Performance" Industrial Technologies and Best Practices Web Site at: http://www.oit.doe.gov

Page 10 of 14

Bonneville Power Administration

Revision No. 1

Pump Drives Power Graphs

Eddy Current Drive Pump Flow Control

ASD Pump Flow Control

120.00
104.45

100.00

% of Design Input Power (kW)

% of Design Input Power (kW)

120.00

89.64

80.00

75.69
62.77

60.00
51.06

40.00

40.75
32.01
25.03

20.00

16.40

17.04

19.98

0.00

102.79

100.00
80.00

79.40

60.00

59.53
43.19

40.00
30.37

20.00

21.07
14.32

15.30

13.05

0.00
0

20

40

60

80

100

120

10

20

% of Design Flow (gpm)

30

40

50

60

70

80

90

100

110

% of Design Flow (gpm) or % of Full Speed(rpm)

Mechanical Speed Pump Flow Control

% of Design Input Power (kW)

120
104.88

100

These power curves 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, 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 pumping system.

96.29
86.46

80

75.81
64.76

60
53.72
43.12

40
33.38
24.92

20
13.51

18.16

0
0

Page 11 of 14

20

40
60
% of Design Flow (gpm)

80

100

120

Values used in spreadsheet

Bonneville Power Administration

Revision No. 1

ADJUSTABLE SPEED DRIVE ENERGY SAVINGS CALCULATOR

~ Pump Applications ~
Enter Nameplate Horsepower:
Enter Nameplate Efficiency:
Enter Motor Load at Pump Design GPM:
Enter Power(KW) at Pump Design GPM:

100.00
95.00
55.00
43.19

hp
%
%
KW

www.cerusind.com
1-800-3543787

Facility Information
Enter Hours per year pump operates:
Enter Energy Charge:

4000
0.05

hrs/yr
$/kwh
Existing Pump Flow Control Method

Select Flow Control

Method Below

Click to go to Pump Power Graphs for additional information

1

1 Throttling Valve
2 Eddy Current Clutch
3 Mechanical (Torque Converter)

4 Bypass, Recirculation Valve

5 Selection 5 allows Measured Power (kW) readings to be used

Duty Cycle

Power Analysis

Savings Analy

Existing System
Enter Percent
Enter
of Design
Percent of
Capacity
Time at this
(GPM)
Capacity
5.0%
5.0%
10.0%
10.0%
10.0%
10.0%
10.0%
10.0%
10.0%
10.0%
10.0%

Totals:

100.0%

P erc ent o f T ime at this C ap acity

0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%

Existing
System
Percent of
Design (KW)

Do Not
Enter Data
Below

ASD System

Existing
System Power
(kW)

55.21
61.39
67.19
72.61
77.65
82.31
86.59
90.49
94.01
97.15
99.91

Percent of
Design (kW)
for ASD
System

ASD System Power

(kW)

27.45
19.12
14.32
13.05
15.30
21.07
30.37
43.19
59.53
79.40
102.79

11.85
8.26
6.19
5.64
6.61
9.10
13.12
18.65
25.71
34.29
44.40

23.85
26.52
29.02
31.36
33.54
35.55
37.40
39.08
40.60
41.96
43.15
142,738.45 Kwh/yr

69,503.14 Kwh/yr

existing

Annual Energy
Savings (Kwh/yr)

2,398.30
3,651.08
9,133.28
10,289.94
10,772.16
10,579.93
9,713.26
8,172.14
5,956.57
3,066.55
-497.91
73,235.31

asd

P erce nt o f T ime at this 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

70
60

60
50

Sample Duty Cycle - LOW PUMP LOADING

60
55

50

40

40

30
25

30
20

20

20

20

15

10

10
0

0
50

75
Percent of Design Capacity
(gpm)

90

30

Percent 50
of Design Capacity (gpm)

70

Summary
Energy Savings:
Cost Savings:
Materials Cost:

$
$

73,235.31 KWH/yr
3,661.77
-

Labor Cost:
Total Cost:
Simple Payback:

$
$

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 s
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

* This is an Excel 2000 file and is approximately 2.5 MB in size.

Page 12 of 14

Bonneville Power Administration

Revision No. 1

ADJUSTABLE SPEED DRIVE ENERGY SAVINGS CALCULATOR

~ Pump Applications ~

ity Information

p Flow Control Method

k to go to Pump Power Graphs for additional information

Selection 5 allows Measured Power (kW) readings to be used in the analysis

Savings Analysis

Annual Energy Cost

Savings ($/yr)

119.92
182.55
456.66
514.50
538.61
529.00
485.66
408.61
297.83
153.33
-24.90
$

3,661.77

P erce nt o f T ime at this C ap acity

used as a guide if the duty cycle is not known)

Sample Duty Cycle - LOW PUMP LOADING

60
55

50

40

30
25

20
15

10
5

0
30

Percent 50
of Design Capacity (gpm)

70

90

Summary

years

tion (BPA) and is intended to be used as an estimation of potential energy savings and
upon more extensive analysis tools than what is provided here.

cbmilan@bpa.gov

Page 13 of 14

Bonneville Power Administration

Revision No. 1

% of Design (kW)

Throttle Valve Power Graphs

Constant Recirculation, Bypass Control

105

100

Throttling Valve Flow Control

125.00

100.00

97.15

94.01

99.91

90.49
86.59

% of Design (kW)

82.31
77.65

75.00

95

72.61
67.19

90

50.00

85

25.00

80
10

20

30

40

50

60

70

% of Design Flow (gpm)

80

90

100

110

0.00
10

20

30

40

50

60

70

% of Design Flow (gpm)

80

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/RevCMS 8121. Curves are representative, not precise, final economic analysis should be based on actual power (kW) measurements of the
pumping system.

Page 14 of 14

Bonneville Power Administration

Revision No. 1