PumpSave 4.4 User`s Manual Energy Savings Calculator for Pump
Contents
1. 62__ Ib ft Static head 1 1100 gpm Efficiency 88 33 jt Max head Ad Existing Flow Control Throttling control C Supply voltage Motor power Motor efficiency r Operating Profile Annual running time 1 1 ee ee SS oo 8 ow om oo ow noo eee Motor and Supply Data 400 x 132_ Hp 95 0 g 8760 h 438h at nom flow 876h at 90 flow 1314h at 80 flow 1752h at 70 flow 1752 h at 60 flow 1314 h at half flow 876h at 40 flow 438h at 30 flow Oh at 20 flow 380 400 415 V Required motor power 14 5Hp including 10 safety margin onan FLOW gpm o KA t t kA e t K2 Pump data System data Measurement Units C Metic Calculated by Calculated for Pump ID Improved Flow Control by ABE Drive series AC5550 v Results Saving percentage Annual energy consumption with existing control method with improved control method Annual energy saving Annual CO2 reduction Energy Consumption 70000 Enurgy Consumed KWA 60000 50000 40000 30000 20000 Throttling control AC Drive 90 80 Power kW 7 0 60 50 40 30 20 ao Flow rate 20 30 40 50 60 70 80 30 100 Throtting contol AC Drive CO2 emissioniunit Economic Data Currency unit Energy pric2. A H 2 H H Q n A pump will always operate where these curves intersect as Graph 1 shows Please notice that the point defined by H and Q is assumed to be known and valid for pump and system curve system curve Hsi Hst Q Qn HnHsi pump curve Hpi Hmax Q Qn Hmax Hn SYSTEM Qn Graph 1 Typical pump and system curves When adjusting the pump speed to control the volume flow the process moves via system curve Hsi Respectively when throttling the pipeline the pump operates continuously at the same speed and the movement of the process is via pump curve Hpi The nominal shaft power of a pump is calculated from the formula 13 p O H 0 981 n p In the calculation sheets calculations are at single points for Q 20 to 100 of nominal pump flow Qn Q is the actual flow H is the total dynamic head at flow Q The efficiency figures are multiplied with k factors witch take into account operating conditions with some accuracy These correcting factors are defined based on experience P Efficiency MOTOR 80 Graph 2 Typical efficiencies Flow This gives the following formulas for power calculations Frequency converter control p Qi Hsi 9 81 Pvsdi np nm kmi kvsdi nvsd where kmi Qi Jone kvsdi table Throttling control assuming constant motor efficiency p Qi Hpi 9 81 Pthi np kpi nm where kpi Qi 2 4 1 44 Qi Qn Qn
3. ON OFF control assuming constant motor and pump efficiency p Qi Hn 9 81 Pow jorr _avg T np nm 14 Unit Conversions Hydraulic control Pixie p Oi Hsi 9 81 np nm nhi where nhi 0 98 Qi 1 Qi 0 75 Hst Hn The rated efficiency of hydraulic coupling is assumed to be 98 The required power for the compared control method is calculated and the energy consumption per year is thereafter calculated from the formula E Tki Pi The formulas above use metric measurement units In the case US units have been selected to be used in entering the data and presenting the results the following conversion factors have been used Nominal volume flow Q gpm 0 22712471 m 3 h Head H ft 0 3048 m Liquid Density D lb ft 0 016018463 kg dm3 Nominal Power P Hp 0 7457 kW Mass weight m lb 0 4536 kg 15
4. TECHNICAL INACCURACIES OR TYPOGRAPHICAL ERRORS CHANGES AND ADDITIONS MAY BE MADE BY ABB FROM TIME TO TIME TO ANY INFORMATION CONTAINED HEREIN THE LICENSEE IS SOLELY RESPONSIBLE FOR DETERMINING THE APPROPRIATENESS OF USING OR DISTRIBUTING THE CALCULATION TOOL AND ASSUMES ANY RISKS ASSOCIATED WITH HIS EXERCISE OF PERMISSIONS UNDER THIS LICENSE Limitation of Liability In no event and under no legal theory whether in tort including negligence contract or otherwise unless required by applicable law such as deliberate and grossly negligent acts shall ABB be liable for any damages including any direct indirect special incidental or consequential damages of any kind arising as a result of this License or out of the use or inability to use the Calculation Tool including but not limited to damages for loss of goodwill work stoppage computer failure or malfunction or any and all other commercial damages or losses even if ABB has been advised of the possibility of such damages Copyright 1994 2005 ABB All rights reserved I accept all the terms of this Agreement I do not accept the terms of this Agreement After having clicked Continue button and accepting the license terms the worksheet will open see Figure 2 where input data is entered and results are presented The language setting is on top right corner The translated words and help texts are taken from Language sheet based on English keywords This manual explains the
5. tool hereafter Calculation Tool published by ABB in accordance with the terms and conditions of this License All intellectual property rights and title to the Calculation Tool shall remain with ABB and no interest or ownership therein is conveyed to Licensee No right to modify even For purposes of error correction adapt decompile or translate the Calculation Tool or create derivative works therefrom is granted to Licensee Except as expressly Praed for in this License no license or right is granted to Licensee directly or by implication inducement estoppel or otherwise Permission to use for information purposes copy and distribute this calculation tool published by ABB is hereby granted on the condition that each copy contains this License Agreement and Copyright Notice in its entirety and that the use of this calculation tool is restricted for information purposes only Even though every effort has been made to ensure a sufficient accuracy of the results in a typical situation the results given by this Calculation Tool must not be perceived as guaranteed energy savings Disclaimer of Warranty ALL INFORMATION CALCULATIONS MADE AND RESULTS WITHIN THIS CALCULATION TOOL ARE PROVIDED AS IS WITHOUT ANY REPRESENTATION OR WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES FOR MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR NON INFRINGEMENT THIS TOOL AND ANY OTHER ABB DOCUMENTATION MAY INCLUDE
6. Energy price 0 1 EUR kWh Economic Results E u E15 1314h athalffow mi E Investment cost 7 000 _JEUR Annual saving E Sl 10 876h at40 flow s Interest rate 4 Payback period eal 5 438h at 30 flow e Service life years Net present value 365 E oj Oh at20 fow a rs 100 Set ie Save calculation a Tag Close program Figure 2 PumpSave view The required data includes system data pump data existing flow control method motor and supply voltage data and operating profile Economic data such as energy price and investment cost is required in order to get figures for investment appraisal Liquid density p kg m3 Enter the density of the liquid at the pump inlet in kilograms per cubic meter The density of water is 1000 kg m3 at 20 C Pump data Hnax system curve Hsi Hst Q Qn HnHsi pump curve Hpi Hmax Q Qn H max Hn SYSTEM Qn Graph 1 Typical pump and system curves Static head Hs m The static head is the difference between the static pressure at the pump discharge and the static pressure at the pump inlet but converted to head It is the net distance that the pumped fluid is lifted but additionally the pressure liquid and gas in the container has to be taken into account while determining the static head Nominal volume flow Qn m3 h Enter the maximum system flow in cubic meters per hour which the existing system will deliver and the pump must reach with existing control PumpSave wi
7. English ones Energy Consumption Finnish 300 000 Deutsch ables Francais Pycckun There are four buttons in the center of the sheet Auto Adjust screen size screen button Send to default printer button Save calculation button and Close program button PumpSave is optimized for desktop area of 1600 1200 pixels If the PumpSave view is not fully visible click the Auto Adjust screen size button This zooms the screen so that it should fit into the visible area It is also possible to zoom the sheet by selecting View Zoom from Excel menu bar To exit the program click the Close program button or click the cross button in the upper right corner of the screen Then Excel will prompt to save the workbook Also you can save a copy of worksheet to a hard disk by selecting File Save as from Excel menu bar and save the calculations and give it a different name Click the Send to default printer button The sheet can also be printed by selecting File and Print from the Excel menus 3 PumpSave worksheet inputs and results General Gi pumpSaves4 xls Compatibility Mode System Data iPumpSave 4 4 Energy saving calculator for pumps All white cells on the calculation sheet are for entering information and data Please use for decimal symbol either comma or decimal point etc according you Excel settings The sheet is filled in by default values to help users to right away find the id
8. PumpSave 4 4 User s Manual Energy Savings Calculator for Pump Drives ACS55 ACS150 ACS310 ACS355 ACS550 ACH550 ACS800 ACQ810 l L a i f S N X X 3AFE 64191691 REV J EN Effective 24 03 2010 Copyright ABB Oy Drives TT 1 General Version 4 4 Version 4 3 Version 4 2 Version 4 1 Version 3 11 PumpSave is a calculation tool running on Microsoft Excel to calcultate the energy savings available when using a variable speed AC drives ABB frequency converter compared to other pump control systems Comparisons are made with throttling control ON OFF control and adjustable speed control using a hydraulic or other type of slipping drive Calculations are based on typical centrifugal pump operating characteristics and some other assumptions Consequently the accuracy of the results is limited The accuracy of the results is also affected by the accuracy of the input data Results should be used only for estimating purposes The results of this program must not be used as the basis for guaranteed energy savings Results of calculations can be printed out When more accurate computing is needed the DrivePump1 2 PC SW from ABB Drives is recommended First multi language revision ACS355 added Added possibility to translate the PumpSave to languages The tables of ABB Drives have been updated for ACS550 ACH550 and new drives added AC310 ACQ810 and minor changes done for look and feel The tab
9. e 0 1 _ S kWh Investment cost 7 000 Interest rate 4 Service life 10 _ years Economic Results 2 Annual saving Payback period Net present value Ops Save calculation ie Close program AB B Figure 3 PumpSave view with US units Nominal volume flow Qn gpm Nominal head Hn ft Maximum head Hmax ft Liquid density lb ft Enter the density of the liquid at the pump inlet in pounds per cubic feet The density of water is 62 4 lb ft default value 11 Motor Data Drive Data Static head ft Nominal Power Hp Nominal Efficiency nm Based on motor power and voltage PumpSave suggests appropriate drive type to be used It is shown on the right side of the Drive Data box If the motor voltage is between 200 and 690 V PumpSave recommends a low voltage AC drive type available in the US markets 12 5 Explanation of Calculations Pump operating point Hmax Hayn Pump drive calculations In this chapter the formulas behind PumpSave calculations are presented The formulas use metric units If the user enters the data in US units PumpSave converts it to metric units first The conversion factors are given in the end of this manual The formula for the pump curve estimate used in calculations is H ai z H rax 2 H rax H Q n This might be somewhat erroneous to submersible and high characteristic speed pumps etc Respectively the system curve used in calculations is
10. ea of worksheet Results are displayed on pale yellow background Figure 2 shows a default calculation sheet ee Measurement Units Input data System data iF metic CUS pecs RW Liquid density 1000 _ kg m Static head 1 m 800000 Pump Data Calculated by ee Nominal volume flow 1100_ m h Efficiency 88 Calculated for gt 305 6 l s Pump ID jag Nominal head 33 m Max head 44 m perme T 300000 Existing Flow Control f Improved Flow Control by ABB Drive series 200000 Throttling control x ACSS50 v 100 000 o4 Motor and Supply Data ACS550 01 246A 4 aoe to Throttling control AC Drive Supply voltage 400v X 2380 400 415 V ea 140 0 Required motor power 1200 Eostn Motor power 132 _ kw 123 6 KW Results 100 0 including 10 safety margin Motor efficiency 95 0 EI Saving percentage ai energy consumption amp 0 0 r Operating Profile with existing control method 40 0 Annual running time 8760 h with improved control method 200 om mw Annual energy saving aa Powis Ei 5 438h atnom flow a Annual CO2 reduction x 2 30 40 50 60 70 80 90 400 El 10 876h at 90 flow C02 emissioniunit a Pain E E15 1314h at 80 flow zy Economic Data E Eo 4752h at 70 fow Ew Currency unit EUR 7 5 A H20 1752h at 60 flow g p
11. lation options Click Continue to close the window Welcome to PumpSave Energy Saving Calculator for Pump Drives E3 PumpSave tool enables you to estimate energy and money savings when replacing traditional pump control methods with a low or medium voltage variable speed AC drive Frequency converter Variable speed AC drive control can be compared to Throttling control On Off control Hydraulic control Please note that the calculations are based on typical centrifugal pump operating characteristics The results should only be used for estimating purposes i Send fobo to ARI il energy fi abb com Conti eae ek PAID ED Copyright ABB Oy Drives Figure 1 Welcoming window of PumpSave Then also a long license agreement text is shown Worksheet License Agreement and Copyright Notice IMPORTANT READ BEFORE COPYING OPENING OR USING Do not copy open or use the Calculation Tool provided under this license agreement License until you have carefully read the Following terms and conditions By copying opening or otherwise using the Calculation Tool you agree to be bound by the terms of this License IF you do not agree to the terms of this License do not copy open or use the Calculation Tool License Agreement and Copyright Notice ABB hereby grants Licensee a non exclusive non transferable royalty free license to use For information purposes copy and distribute this energy savings calculation
12. les of ABB Drives have been updated and user manual corrected to the level of current PumpSave PumpSave 4 0 did not have a valid user manual Most data fields are populated with default values to help users Version 3 11 fixes a bug that affected energy calculations in the previous version The calculation for ON OFF control energy usage ignored motor efficiency given by the user assuming 100 motor efficiency This omission has now been corrected 2 Starting and Running the Program Software Required Files Provided Installation Opening the Workbook Microsoft Excel 97 or later is required to run the energy calculation workbook With Microsoft Office Excel 2007 the workbook runs on compatibility mode Also you shall enable the running of macros The PumpSave files for pump drive calculations are incorporated into Excel workbook named originally PumpSave44 xls No installation is required but the workbook is can be copied to a hard disk and short cut arranged to desktop Start Excel as usual For pump calculations open PumpSave44 xls Sometimes it will open in Full Screen mode Hence the usual Excel toolbars are not visible Full Screen mode can be disabled and enabled by selecting Full Screen from the View menu With Excel 2007 the hitting the Ecs will open the ribbon As PumpSave is opened a welcome window is displayed Figure 1 shows the welcome window for PumpSave The welcome sheet presents three comparative calcu
13. ll assume that exactly the same flow has to be delivered also with AC drive The energy saving calculation is based on flow rates that are equal to or less than Q The entered value is also shown in liters per second 1 I s 3 6 m h Nominal head Hn m Enter the head in meters that must be generated by the pump to produce the given nominal volume flow Q considering the system curve The value must be determined from the pump curve and system curve intersection One assumption which PumpSave makes is that the system curve with existing control and AC Drive control are the same In reality this is seldom the case In DrivePump SW the two are separate values Maximum head Hmax M Enter the discharge head pressure that will be developed by the pump at full speed and zero flow The value must be determined from the pump curve If the pump curves look complicated select a Hmax which together with Hn define a nice second order curve in the range 20 100 Qn Efficiency n Enter the efficiency of the pump at volume flow Qn The efficiency value should be given with the impeller which will be used Existing control method Motor Data Existing Control Method Pick the existing control method that you want to compare with ABB AC Drive control The control method is selected from the drop down list on the upper left part of the sheet The options are throttling on off control and hydraulic control The smaller energy usage of fre
14. nter the efficiency for operation at the maximum applied load Results Operating profile Economic Data Annual running time In other words this is the total operating time per year h Enter the estimated number of hours that the pump is expected to run during a year s time For 24 hour 365 day operation enter 8760 hours Operating Time at Different Flow Rates Enter the estimated time as a percentage of the total operating time for operation at each of the listed flow rates from 100 to 20 of nominal volume flow Leave blank or enter zero for flow rates that are not used The sum of the entered percentages should be 100 A figure under the white cells shows if the sum equals 100 If it does not a comment THIS SUM MUST EQUAL 100 shows Currency Specify here the currency to be used in calculations The default unit is the Euro EUR Energy price per kWh Enter the price of energy per kilowatt hour kWh The PumpSave program does not have provisions for calculating demand charges To estimate energy cost including demand charges enter the average cost of energy per kWh including average demand charges Investment cost Enter the estimated additional cost of purchasing and installing a variable speed AC drive as compared to the alternative method of flow control used in the comparison Use the same currency units as entered for energy cost This entry will be used to calculate the direct payback time Interes
15. quency converter is compared to a large energy required by Throttling which means the liquid flow control is made by throttling valve and motor and pump is running at full speed and pressure e ON OFF which means ON OFF duty is adjusted according to flow requirements and a reservoir is available The control can t be as good as with speed control When pump and motor is running they run at full speed e Hydraulic which is based on hydraulic drive or some other type of slipping drive such as an eddy current magnetic coupling drive The motor is running with full speed but with slip the pump shaft is controlled PumpSave is computing from pump data the required motor output power including 10 thermal margin Based on this number you may enter the Motor power Motor power kW Enter the nameplate power rating of the motor This is used to select the proper drive rating The program uses calculated power demand to determine energy savings Supply voltage V Enter the supply voltage used in application The value should be between 115 1 ph to 690 V 3 ph This is used to screen out some drive types Motor efficiency nm Enter the motor efficiency from the motor nameplate or from other data supplied by the motor manufacturer Use the efficiency for full load operation on fixed frequency utility power The program will adjust the efficiency for Operation at reduced speeds and loads If the motor is oversized for the application e
16. t rate This is the compensation for capital in the net present value calculation Service Life years The expected service life of the drive Also this is required for the net present value calculation The results of the calculations include the estimated annual energy consumption for the existing control method and for AC drive control the difference of these two which equals the annual energy saving achieved by using a variable speed AC drive PumpSave also estimates the reduction in carbon dioxide CO emissions due to the reduced electricity consumption CO is the most important of the greenhouse gases which cause a global environmental problem called the climate change Payback period is calculated for the investment in the drive as compared to the alternative method of flow control Net present value is also calculated provided that the user enters an interest rate and service life Energy amp environmental Energy Consumed graph kWh The calculated energy used annually with the existing control method and using a frequency converter for flow control are both illustrated in two column chart Saving percentage The reduction in electricity costs in percents This is also of course the energy saving in percents Annual energy consumption kWh These are shown for both with existing control method and improved control method Annual energy saving kWh This is the energy difference in favor of frequency conver
17. ter control Annual CO reduction kg The reduction in carbon dioxide CO2 which results from the reduced energy consumption due to variable speed control Carbon dioxide CO2 is the primary greenhouse gas causing global warming The CO reduction depends on the COz emission per unit which should reflect the way and emissions the electricity used has been generated with The per unit emission is given in kg kWh consumed and it can be altered by the user Economic results Annual money saving This is how much money you save thanks to the variable speed control by AC drive Money saving comes in the form of smaller electricity bill Payback period This direct payback time shows how many years the investment has paid itself back Net present value Net present value NPV is a more advanced method for analyzing investments than the payback period rule If the NPV is positive then the investment should be accepted 10 4 PumpSave calculations with US Units Input Data with US Units The initial data presented in the following consists of the same elements as above but is entered using US measurement units The following applies when US Units is selected In the following the changes to non SI are only explained System Data Liquid density Pump Data Nominal volume flow Nominal head PumpSave44 xls Compatibility Mode 44 Energy saving calculator for pumps
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