FanSave 4.4 User`s Manual Energy Savings Calculator for Fan
Contents
1. Al E 20 1752h at 60 flow 510 FE 15 1314h at half flow So q Em0 876h at 40 flow 10 El 5 438h at 30 flow w l Oh at 20 flow a 100 Fan data Motor Data Results Annual CO Reduction Ib Save Send to Close calculation default printer sie A ED ED PAGED 13 5 Explanation Fan performance curves System curve of Calculations Fan performance can be defined from its performance curves 1 e pressure curve Qv ptF curve and power curve Qv Pr curve Different fan types have different shaped performance curves Additionally the position of the curves depends on gas density and rotation speed For these reasons the performance curves are often presented as sets of curves with different parameters The manufacturer of the fan provides these performance diagrams The pressure curve of the fan can also be referred to as the fan curve The suitability of a fan to a certain duct system depends partly on the form of the fan curve All the calculations of FanSave are based on parabolic fan curve The useful mechanical power transferred into the volume flow is called air power Py It is proportional to the gas volume flow compression factor and total fan pressure For low pressure fans the compression factor 1 The impeller power Pp also called shaft power i e the mechanical power necessary for rotating the fan is then obtained by taking the fan efficiency into account For all centrifugal fans the2. Voltage control is applicable only for fans with lower unit powers lt 3kW Two speed motor two sets of windings 1 2 Dahlander connection which means larger motor compared to one speed motor Cyclic on off which means ON OFF duty is adjusted according to flow requirements and it is acceptable from application point of view The control can t be as good as with speed control When motor and fan are running they run at full speed Inlet box damper is based on damper control Pitch adjustment for axial fans Inlet vanes for centrifugal fans Vane control is done by inlet vane installed at the fan inlet Pitch control is by adjusting the pitch angle of axial flow fan Motor data FanSave 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 a
3. will assume that exactly the same flow has to be delivered also with AC Drive The energy saving calculations will be based on flow rates that are equal to or less than Qvn Pressure Increase pir Pa Required pressure increase of the fan for the given nominal volume flow Q Value is determined from the fan curves and system curve intersection If pressure is more than 5000 Pa FanSave will indicate this by red color and It is better to compute these case manually Efficiency n Enter the nominal efficiency of the fan at nominal volume flow Efficiency n Efficiency of the transmission method e g belt transmission If the fan has been connected directly to the motor use 100 Existing Flow Control 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 control options are Outlet damper Slip coupling Voltage Two speed motor Cyclic on off Inlet box damper Inlet vanes 1 speed vane 2 speed vane and Pitch control The smaller energy usage of frequency converter is compared to a large energy required by Outlet damper control which control the volume flow by throttling it with a damper Slip coupling which control the fan speed with slippage by hydraulic eddy current technology Voltage control which will make the motor voltage lower and make the induction motor to have larger slip Note
4. impeller power increases as the volume increases This connection is presented in the power curve of the fan Further on the electric fan power is calculated by taking the motor and drive efficiencies into account All the duct systems have their special performance curve system curve dependent on the resistances in the duct In a turbulent flow all the resistances caused either by friction or various duct elements are proportional to the square of the volume flow From this follows that the resistance of the duct system i e system curve often complies with the same rule Especially in industrial processes it is likely to encounter also system curves with an additional constant pressure and previously mentioned changing pressure The calculations of FanSave are based and valid on the basic system curve without any constant pressure When adjusting the fan speed to control the volume flow the process moves via system curve a Respectively when throttling the duct the fan operates continuously at the same speed and the movement of the process is via fan curve b 14 Control methods Efficiencies For FanSave calculations the most important control methods to control the fans during operation have been selected Fig 4 below shows the relationship of the electric fan power compared to the volume flow in connection with these control methods The control method presentations are average examples used in calculations P f flo
5. ABILITY FITNESS FOR A PARTICULAR PURPOSE OR NON INFRINGEMENT THIS TOOL AND ANY OTHER ABB DOCUMENTATION MAY INCLUDE 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 4 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 Th
6. FanSave 4 4 User s Manual Energy Savings Calculator for Fan Drives ACS55 ACS150 ACS310 ACS355 ACS550 ACH550 ACS800 3AFE 64232681 REV JEN 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 1 FanSave is a calculation tool running on Microsoft Excel to calculate the energy savings available when using a variable speed AC drive frequency converter compared to other fan control systems Comparisons can be made with damper control pitch control single speed vane control and 2 speed vane control Calculations are based on typical fan operating characteristics 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 First multi language revision ACS355 added Added the possibility to translate FanSave to languages The tables of ABB Drives have been updated for ACS550 ACH550 and new drives added AC310 and minor changes done for look and feel Also a small change written for 2 speed motor The tables 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 popul
7. Nominal volume flow 3 000 00 cfm Calculated for 40 Efficie Fan ID 30 Pressure increase 20 in H20 lt 20 in 90 Ae Flowrate r Transmission Existing Flow Control 100 0 1200 1500 1800 2100 2400 2700 3000 AC Drive Efficiency e Motor and Supply Data Improved control by ABB drive aa ACS550 v 600 900 ACS550 U1 023A 4 I ey inlet vanes Results Specific fan power Saving percentage Annual energy consumption with existing control method with improved control method Annual energy saving Annual CO2 reduction C02 emission Energy Gonsciniesd kiy Inlet vanes r Economic Data Currency Energy price 0 10 __ EUR kWh Investment cost 3000 EUR Interest rate 5 0 Service life 10 0 years Economic Results Annual saving Payback period Net present value Auto adjust screen size Figure 3 FanSave view with US units Nominal Volume Flow Q cfm Motor Power Nominal Power P Hp Supply voltage 40V ets 380 400 415 V Q Required motor power Motor power 12 lHp 11 4 Hp including 10 safety margin Motor efficiency 93 0 EJ rOperating Profile Annual running time 8760 jh y a 5x l 5 438h at nomflow 2 amp 10 876h at 90 flow zw D E T5 1314h at 80 flow 2m E F eal 20 1752h at 70 flow Sa
8. a of worksheet Results are displayed on pale yellow background Figure 2 shows a default worksheet Fan Data Fan type Centrifugal w Nominal volume flow 10 00 m s 36000 m h Pressure increase 3000 Pa Transmission Existing Flow Control ____ Energy saving calculator for fans English Z Energy Consumption 40 0 Measurement Units 35 0 Denis ai Metric cus 30 0 Impeller type Forward curved F Y BO Calculated by 20 0 Calculated for Efficien Fan ID 5 0 Improved control by ABB drive 00 Flow rate ACS550 z 3 4 T 8 Hi Copy to mmm E F Inlet vanes AC Drive ACS550 01 072A 4 I clipboard v Efficiency 100 0 Inlet vanes ad Motor and Supply Data i Supply voltage 4009 X 380 400 415 V rE FMM Required motor power Motor power 37 kW 36 3 KW Specific fan power eats including 10 safety margin Motor efficiency 93 0 H Saving percentage bia i con i 100 000 Operating Profile with existing control method Annual running time 8760 h with improved control method oR om 7 s Annual energy saving isos l 5 438h atnomfow 0 Annual CO2 reduction gj Eio 876h at 90 flow s C02 emission ee p ELi 1314h at 80 flow i Economic Data F amp 20 1752h at 70 flow d Currency EUR Ec
9. abulated with following multipliers Slip Flow 0 2 0 146 0 3 0 163 0 4 0 22 0 5 0 297 0 6 0 386 0 7 0 505 0 8 0 626 0 9 0 773 Outlet damper Flow F 0 2 0 38 0 3 0 38 0 4 0 395 0 5 0 45 0 6 0 525 0 7 0 615 0 8 0 715 0 9 0 84 Voltage 0 094 0 156 0 223 0 331 0 44 0 563 0 703 0 846 Outlet damper B 0 49 0 57 0 655 0 723 0 79 0 855 0 91 0 96 Two speed 0 225 0 225 0 225 0 225 0 225 1 1 1 Outlet damper R 0 49 0 57 0 655 0 723 0 79 0 855 0 91 0 96 Cycli c 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 Inlet damper 0 47 0 5 0 54 0 58 0 62 0 67 0 75 0 84 Pitch 0 339 0 36 0 394 0 446 0 483 0 559 0 636 0 763 Inlet vanes 0 339 0 36 0 394 0 446 0 483 0 559 0 636 0 763 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 Pressure increase Pr Inlet Static Pressure pta Nominal Power Mass weight P cfm 2118 88 m s in H20 249 08194 Pa psi 6894 7573 Pa Hp 0 7457 kW Ib 0 4536 kg 17
10. ansferable royalty free license to use For information purposes copy and distribute this energy savings calculation 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 MERCHANT
11. ated with default values to help users Fan type can be selected The options are centrifugal and axial flow If the user selected centrifugal fan type impeller type can be selected The options for impeller type are forward curved backward curved and radial blades Supply voltage was called Motor voltage in version 3 1 The possibility of using US measurement units has been added The AC drive types available in the North American market have been added The term CO emissions is used instead of GHG emissions in version 3 1 2 Starting and Running the Program Software Required 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 Files Provided The FanSave files for fan drive calculations are incorporated into Excel workbook named originally FanSave44 xls Installation No installation is required but the workbook is can be copied to a hard disk and short cut arranged to desktop Opening the Workbook Start Excel as usual For fan calculations open FanSave44 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 FanSave is opened a welcome window is displayed Figure 1
12. e translated words and help texts are taken from Language sheet based on English keywords This manual explains the 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 FanSave is optimized for desktop area of 1600 1200 pixels If the FanSave 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 FanSave worksheet inputs and results General i FanSave amp All white cells on the worksheet 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 ide
13. mpared 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 Interest Rate This figure is the compensation of capital that is used in net present value calculation Service Life years The expected service life of the drive Also this is required for the net present value calculation Results 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 FanSave 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 Electric power consumption of fan graph kW The calculated power used with the existing control method and using a frequency converter are both illustrated xy chart Electric power consumption of fan fhlet vanes o AC drive control 2 3 4 5 6 7 8 9 10 Air fl
14. onomic Results A amp 20 1752h at 60 flow g Energy price 0 10 __ EUR kWh 7 amp 15 1314h at half flow a 5 Investment cost 3 000 EUR Annual saving T A 10 876h at40 flow Interest rate 5 0 Payback period l 5j 438h at30 flow 3 Service life 10 0 years Net present value E J Oh at 20 flow Auto adjust S Sendt 100 screen size E default na Sone prog 4k 0D ED FPAIDED Figure 2 FanSave view Input data The input data includes information about fan transmission existing control method motor operating profile Economic data such as energy price and investment cost is required in order to get figures for investment appraisal Fan data Fan type Fan type can be selected The options are centrifugal and axial flow If the user selected centrifugal fan type impeller type can be selected The options for impeller type are forward curved backward curved and radial blades Transmission Centifugal fans with reasonable low pressure gas can be computed with FanSave The computing of high pressure fans does not come correct because the compression of the gas can not be simply modeled Impeller type Centrifugal fans of different blade shapes behave differently SYSTEM Graph 1 An example of typical fan and system curves Nominal Volume Flow Qn m3 s Enter the maximum system volume flow in cubic meters per second which the existing system will deliver and fan must reach with existing control FanSave
15. owrate 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 converter control Annual CO reduction kg The reduction in carbon dioxide CO3 which results from the reduced energy consumption due to variable speed control Carbon dioxide CO is the primary greenhouse gas causing global warming The CO reduction depends on the CO2z emission per unit which should reflect the way and emissions the electricity used has been generated with The 10 per unit emission is given in kg kWh consumed and it can be altered by the user Economic results Additional data 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 Gas Density D kg m3 The normal air density is 1 20kg m3 For other temperatures and humidities use available monographs to find out the correct density o
16. r calculate it using the following formula This can be used if fan curves are given with some data and the gas in question is somewhat different Table 1 gives air densities for temperatures from 0 to 450 C D D Te Psat D where D required density T Pyar Dx known density T temperature at required density Tx known temperature Psa pressure at required density Psa2 known pressure 11 Table 1 Density of dry air as function of temperature at normal air pressure 1013 mbar Temperature Density C kg m 0 1 2930 10 1 2471 20 1 2045 30 1 1647 40 1 1267 50 1 0924 60 1 0595 70 1 0287 80 0 9998 90 0 9719 100 0 9458 120 0 8980 140 0 8535 160 0 8150 180 0 7785 200 0 7457 250 0 6745 300 0 6157 350 0 5662 400 0 5242 450 0 4875 12 4 FanSave worksheet 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 FanSave 4 4 Energy saving calculator for fans English Energy Consumption n 90 P i Power _Fan Data Measurement Units 80 cease C Metric us Ee Fan type centrifugal z Impeller type Forward curved F x n o Calculated by 0
17. shows the welcome window for FanSave The welcome sheet presents four comparative calculation options Click Continue to close the window Welcome to FanSave Energy Saving Calculator for Fan Drives gt FanSave tool enables you to estimate energy and money savings when replacing traditional Fan control methods with a low or medium voltage variable speed AC drive Frequency converter Variable speed AC drive control can be compared to Damper control throttling Vane control single speed 2 speed vane control Pitch control Please note that the calculations are based on typical centrifugal fan for operating characteristics The results should only be used For estimating purposes Send Feedback to energy fi abb com AL EDER Copyright ABB Oy Drives Continue Figure 1 Welcoming window of FanSave 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 tr
18. t reduced speeds and loads If the motor is oversized for the application enter the efficiency for operation at the maximum applied load Operating profile Annual running time In other words this is the total operating time per year Enter the estimated number of hours that the fan 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 Drive data Economic Data User should select the drive family from drop down box FanSave will pick the drive rating based on motor power and voltage 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 FanSave 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 co
19. w 1 1 1 0 9 0 8 0 7 0 6 Damping osf er 1 speed vane meee ere sense 2 speed vane Ot a ah es Pitch Ag Frequency converter s control 0 1 Flow O S 28 8 2 28s Figure 4 The power curves of flow control methods The given values are used in the formulas Further as shown in the formulas the efficiency of the system depends on the given efficiencies of fan mechanical transmission motor and drive and on the adjustment method specific correcting factor These correcting factors have been derived empirically 15 FanSave calculations The following formulas are used for power calculations The impeller power i e nominal shaft power of a fan is calculated from the formula Pf kp Qvn ptF where kp is compression factor kp 1 0 35 ptF nk pta The electrical power for different control methods and for different flow rates is calculated as follows Frequency converter control nominal power Pvs100 eE o where nk nt nm nd where nk fan efficiency nt transmission efficiency nm motor efficiency nd drive efficiency The power consumption on lower flow levels are tabulated Flow Multiplier 0 2 0 035 0 3 0 055 0 4 0 095 0 5 0 155 0 6 0 24 0 7 0 37 0 8 0 515 0 9 0 74 Other control types Pd1o0 nk nt nm where nk fan efficiency nt transmission efficiency nm motor efficiency 16 Unit Conversions The power consumption on lower flow levels are t
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