BUILDINGTECHNOLOGIESPROGRAMApril29‐30,2014ASRACPumpsWorkingGroupMetric:TestingandCalculations2PrimaryDiscussionReviewofMetricandRelationshiptoStandardOverviewofPERTestProcedureforControlledversusUncontrolledPumpsOtherRemainingIssues/TopicsTestProcedureOptions•Calculation‐basedmethod-Howtoaccountformotorefficiencyatpartloadandcontrols•Testing‐basedmethodLoadPointOptionsWeightingOptionsOtherDenominatorOptionsOverview3MetricGoals1. Beobjectivelymeasureable2. Representtheperformanceofthecoveredproduct3. Differentiateperformanceamongpumpmodelsandpumpconfigurations(e.g.pumpssoldwithcontrols)4. Communicateinformationaboutpumpperformancetotheconsumer–Maynotbealltheinformationaconsumerusestomakeadecision5. ComparetheefficiencyofagivenpumpmodeltoaminimumstandardlevelMetricTestProcedureTestedPerformanceofPumpATestedPerformanceofPumpBEnergyConservationStandardMinimumStandardLevelBarePumpEfficiencyorEnergyUseMotorEfficiencyorEnergyUseControlsEfficiencyorEnergyUse‘Pump’EfficiencyorEnergyUse=4MetricTestProcedureTestedPerformanceofPumpATestedPerformanceofPumpBEnergyConservationStandardMinimumStandardLevelScopeofSlides•ThisslidedeckandthePERCalculatoraddresshowthemetriciscalculatedinthetestprocedureforagivenpumpmodel.5MetricApplicabilitytoPumpConfigurationsPumpConfigurationBare Pump* BarePump+ Motor BarePump+Motor+Controls

Metric CoverageBarePump MEIDoesnotincludemotorefficiencyDoesnotdescribecontrollossesorbenefitsBarePump+DriverPERCL(w/ std.driver)PERCLDoesnotdescribecontrollossesorbenefitsBarePump+Driver+ControlsPERCL(w/ std.driverandcontrols)PERCL(w/std.controls)PERVL

PumpMotor PumpMotorControl Pump•Defineaunique,butsimilar,metricforcontrolledversusuncontrolledpumps•Uncontrolledpumps‐>ConstantLoadPumpEnergyRating(PERCL)•Controlledpumps‐>VariableLoadPumpEnergyRating(PERPL)*Pumpssoldwithnon‐electricdrivescouldberatedasbarepumps6PERTestProcedurePumpEnergyRating(PER)CLandFL:equallyweightedaverageelectricinputpowertothe‘pump’measured(orcalculated)atthedriverinputor,whenpresent,controlsinput,overaspecifiedloadprofile:Where:•PER=PumpEnergyRating(hp);•wi=weightateachloadpointi;•Pini=powerinputtothe“pump”atthedriver,inclusiveofthecontrolsifpresent,(hp);•Denominator=minimallycompliantuncontrolledpump;and•i=Percentageofflowatthebestefficiencypoint(BEP)ofthepump.•i=110%,100%,75%ofBestEfficiencyPoint(BEP)flowatnominalspeedforuncontrolledpumps•i=25%,50%,75%,and100%ofBEPflowatnominalspeedforpumpssoldwithmotorsandcontrols.ࡾࡱࡼࡸࢂ/ࡸ࡯ൌ∑߱௜ܲ௜௡௜௜݌݉ݑܲ	݈݈݁݀݋ݎݐ݊݋ܷ݊ܿ	ݐ݈݅ܽ݊݌݉݋ܥ	ݕ݈݈݅݊݅݉ܽܯ7DeterminingPERCLforanUncontrolledPump•PumpPerformance–Pivaluesarethetestedshaftinputpowertothepump(speedxtorque)ateachloadpointi•i=75%,100%,and110%offlowrateatBEPofthepump•Equalweighting•MotorPerformance(Losses)–Lratedisthefullloadlossesofamotorthatispairedwiththepumpforpumpssoldwithmotors–LratedisthefullloadlossesofanenclosedmotorthatisminimallycompliantwithDOE’smotorregulations(10CFR431.25)forgeneralpurposemotors(subtypeI)forallpumpsexceptESCCandgeneralpurposemotors(subtypeII)forESCCpumpsܲܧܴ ൌఠబ.ళఱ௉೔೙బ.ళఱାఠಳಶು௉೔೙ಳಶುାఠభ.భ௉೔೙భ.భ௉ாோ೘೔೙ൌ߱଴.଻ହܲ௜௡଴.଻ହ൅ ߱஻ா௉ܲ௜௡஻ா௉൅ ߱ଵ.ଵܲ௜௡ଵ.ଵ߱଴.଻ହܲு௬ௗ௥௢,଴.଻ହ0.95 ∗ ߟ௣௨௠௣൅ ܮ଴.଻ହ൅ ߱஻ா௉ܲு௬ௗ௥௢,஻ா௉ߟ௣௨௠௣൅ ܮ஻ா௉൅ ߱ଵ.ଵܲு௬ௗ௥௢,ଵ.ଵ0.985 ∗ ߟ௣௨௠௣൅ ܮଵ.ଵ=భయ∗௉బ.ళఱା௅బ.ళఱାభయ∗௉ಳಶುା௅ಳಶುାభయ∗௉భ.భା௅భ.భభయ∗ುಹ೤೏ೝ೚,బ.ళఱబ.వఱ∗ആ೛ೠ೘೛ା௅బ.ళఱାభయ∗ುಹ೤೏ೝ೚,ಳಶುആ೛ೠ೘೛ା௅ಳಶುାభయ∗ುಹ೤೏ೝ೚,భ.భబ.వఴఱ∗ആ೛ೠ೘೛ା௅భ.భ•NoControlsPerformance8DeterminingPERVLforaControlledPumpൌ ܴܧܲ1η௖௧௥௟߱଴.ଶହܲ௜௡଴.ଶହ൅ ߱଴.ହ଴ܲ௜௡଴.ହ଴൅ ߱଴.଻ହܲ௜௡଴.଻ହ൅ ߱஻ா௉ܲ௜௡஻ா௉߱଴.଻ହܲு௬ௗ௥௢,଴.଻ହ0.95 ∗ ߟ௣௨௠௣൅ ܮ଴.଻ହ൅ ߱஻ா௉ܲு௬ௗ௥௢,஻ா௉ߟ௣௨௠௣൅ ܮ஻ா௉൅ ߱ଵ.ଵܲு௬ௗ௥௢,ଵ.ଵ0.985 ∗ ߟ௣௨௠௣൅ ܮଵ.ଵ=ଵ஗೎೟ೝ೗భర௉೔೙బ.మఱାభర௉೔೙బ.ఱబାభర௉೔೙బ.ళఱାభర௉೔೙ಳಶುఠబ.ళఱುಹ೤೏ೝ೚,బ.ళఱబ.వఱ∗ആ೛ೠ೘೛ା௅బ.ళఱାఠಳಶುುಹ೤೏ೝ೚,ಳಶುആ೛ೠ೘೛ା௅ಳಶುାఠభ.భುಹ೤೏ೝ೚,భ.భబ.వఴఱ∗ആ೛ೠ೘೛ା௅భ.భ•PumpPerformance–Pivaluesarethetestedshaftinputpowertothepump(speedxtorque)ateachloadpointi•i =25%,50%,75%,and100%offlowrateatBEPofthepump•Equalweighting•MotorPerformance(Losses)–Lratedisthefullloadlossesofamotorthatispairedwiththepumpforpumpssoldwithmotors•ControlsPerformance–Benefitiscapturedincalculationofbareshaftinputpower–Couldstillaccountfordriveefficiency9MinimallyCompliantPump•PERforaminimallycompliantpump–BasedonPERStandardsetthroughStandardsanalysis–Assumesapumpcurveshapefortheminimallycompliantpumpandalwaysassumesnocontrols–Motorlossesarethatofaminimallycompliantenclosedmotorfortheappropriatepumptype–Theminimallycompliantpumpefficiencyiscalculatedforeachpumptypebasedonafunctionofflowandspeedܲܧܴ௡௜௠ൌ ߱଴.଻ହܲு௬ௗ௥௢,଴.଻ହ0.95 ∗ ߟ௣௨௠௣,௠௜௡൅ ܮ଴.଻ହ൅ ߱஻ா௉ܲு௬ௗ௥௢,஻ா௉ߟ௣௠௨௣൅ ܮ஻ா௉൅ ߱ଵ.ଵܲு௬ௗ௥௢,ଵ.ଵ0.985 ∗ ߟ௣௨௠௣൅ ܮଵ.ଵߟ௣௨௠௣ൌ 88.59 ∗ lnܰݏ ൅ 13.46 ∗ lnܳ௠௘௧௥௜௖െ 11.48 ∗ lnܰݏଶെ 0.85 ∗ lnܳଶെ 0.38 ∗ lnܰݏ∗ lnܳ െܥ•Where:–Nsisthespecificspeedofthepumpinmetricunits,–QistheflowrateofthepumpatBEPinm3/hr,–CistheC‐valueofthesurface,whichissetbasedonthespeedofrotationofthepump,and–Allvaluesareforthepumpat50Hz10OptionsforDeterminingPERFLforaControlledPumpܴܧܲ஼௅ൌ߱଴.଻ହܲ௜௡଴.଻ହ൅ ߱஻ா௉ܲ௜௡஻ா௉൅ ߱ଵ.ଵܲ௜௡ଵ.ଵ߱଴.଻ହܲு௬ௗ௥௢,଴.଻ହ0.95 ∗ ߟ௣௨௠௣൅ ܮ଴.଻ହ൅ ߱஻ா௉ܲு௬ௗ௥௢,஻ா௉ߟ௣௨௠௣൅ ܮ஻ா௉൅ ߱ଵ.ଵܲு௬ௗ௥௢,ଵ.ଵ0.985 ∗ ߟ௣௨௠௣൅ ܮଵ.ଵܴܧܲ௏௅ൌ1η௖௧௥௟߱଴.ଶହܲ௜௡଴.ଶହ൅ ߱଴.ହ଴ܲ௜௡଴.ହ଴൅ ߱଴.଻ହܲ௜௡଴.଻ହ൅ ߱஻ா௉ܲ௜௡஻ா௉߱଴.଻ହܲு௬ௗ௥௢,଴.଻ହ0.95 ∗ ߟ௣௨௠௣൅ ܮ଴.଻ହ൅ ߱஻ா௉ܲு௬ௗ௥௢,஻ா௉ߟ௣௨௠௣൅ ܮ஻ா௉൅ ߱ଵ.ଵܲு௬ௗ௥௢,ଵ.ଵ0.985 ∗ ߟ௣௨௠௣൅ ܮଵ.ଵPERConstant Load PERVariableLoadPumpPerformancePi=measuredshaftinputpowertothepump(speedxtorque)ateachloadpointiWhere:i = 75%,100%,and110%offlowrateatBEPofthepumpandequalweightingPi=calculatedshaftinputpowertothepumpbased onaffinitylawsateachloadpointiWhere:i =25%,50%,75%,and100%offlowrateatBEPofthepumpandequalweightingMotorPerformance(Losses)LratedisthefullloadlossesofamotorthatispairedwiththepumpforpumpssoldwithmotorsorthefullloadlossesofanenclosedmotorthatisminimallycompliantwithDOE’smotorregulations(10CFR431.25)forgeneralpurposemotors(subtypeI)forallpumpsexceptESCCandgeneralpurposemotors(subtypeII)forESCCpumpsLratedisthefullloadlossesofamotorthatispairedwiththepumpandlossesarecalculatedforthereducedloadingwithspeedreductionControlsPerformanceNocontrols Benefitiscapturedincalculation ofbareshaftinputpower.Driveefficiency=96%11ItemstoDiscussattheNextMeeting/Webinar(5/14)•Metricnomenclature•ComparisonofMEIandPER•Impactoftestprocedureandmetriconstandard•Definitionofbasicmodel•Examplesfordifferentpumpconfigurationsandrevisedcalculator•ImplementationofPERCLandPERVL–Labeling/markinglogistics,includingsalesanddistributionchannels–Additionalreportedinformationorlabelinformation–Whoisthemanufacturer?–Marketimpacts,especiallyapplicationtoutilityprograms•Motoranddriverpartloadlossfactor•Testingvscalculationoptions•Testingburden•Certificationandenforcementissues12PERTestProcedureOptionsPumpConfigurationBare Pump*BarePump+Motor BarePump+Motor+Controls

Test Procedure OptionsTestedBarePump+CalculationsTestedbarepumpperformance +DOEminimumefficiencymotorwithassumedpartloadlossesTested barepumpperformance+manufacturermotorwithassumedpartloadlossesTestedbarepumpperformance+manufacturermotorwithassumedpartloadlosses+LoadControlFactorTestedPumpwithManufacturerMotorN/ATested performanceofbarepumpwithmanufacturermotor(wiretowater)Tested performanceofbarepumpwithmanufacturermotor(wiretowater)+LoadControlFactorTestedPumpwith MotorandControlsN/A N/ATested performanceofbarepumpwithmanufacturermotorandcontrols(followsystemcurve)

PumpMotor PumpMotorControl Pump*Pumpssoldwithnon‐electricdrivescouldberatedasbarepumps13AccountingforMotorLossesThefractionalmotorlossesateachloadpointi(Li)arecalculatedastheratedfullloadmotorlosses(Lrated)multipliedbythepart‐loadlossfactor(yi),whichiscalculatedasacubicpolynomial*oftheloadfractiononthemotor(xi):ܮ௜ൌ ܮ௔௥௧௘ௗ∗ ݕ݅ ൌ ܮ௔௥௧௘ௗ∗ܽ∗ݔ௜ଷ൅ܾ∗ݔ௜ଶ൅ܿ∗ݔ௜൅ ݀ൌ ܮ௔௥௧௘ௗ∗ܽ ∗ܲ௜݁ݖܵ݅ݎ݋ݐ݋ܯଷ൅ܾ∗ܲ௜݁ݖܵ݅ݎ݋ݐ݋ܯଶ൅ܿ∗ܲ௜݁ݖܵ݅ݎ݋ݐ݋ܯ݀ ൅Where:•Li=thefractionalloadlossofthemotoratloadpointi(hp);•Lrated=theratedfullloadmotorlossesasdeterminedinaccordancewiththeDOEtestprocedureformotorsat10CFR431subpartB(hp);•yi=thepart‐loadlossfactor;•xi=theloadfractionforthemotorateachloadpointi;•Pi=theshaftinputpowertothebareshaftpump(hp);•MotorSize =thenominalratedoutputpowerofthemotor(hp);and•i=Percentageofflowatthebestefficiencypoint(BEP)ofthepump.*Adifferentcubicpolynomial(i.e.differenta,b,c,anddcoefficients)areassumedbasedontherotatingspeed(2‐polevs.4‐pole)andmotordesign(ODPvs.TEFC)14“Denominator”Options“Denominator” Units Pros ConsNoDenominator Hp orkWhRepresentativeoftheenergyconsumptionofthatpumpinthefield.Strong function offlowandspecificspeed.Notcomparableacrosspumpsofdifferentflows/specificspeeds.Less strong function offlowandspecificspeed.ReferenceshaftpowerforminimallycompliantbarepumpwithminimallycompliantmotorDimensionlessResultsinvaluebetween0and1(moreintuitive).Clearlyindicatesperformance ofapumprelativetoabaseline.Inherentlyrequiresdesignationofminimallycompliantpump(i.e.,MEI).Mayover‐orunder‐representthebaselineefficiencyforsomepumps.MarketaverageshaftpowerwithminimallycompliantormarketaveragemotorDimensionless Indicatesperformanceofapumprelativetothemarket.Locksinthemetrictotheperformanceofpumpsinthemarketatagivenpointintime.Doesn’tlimitmetricvaluesbetween0and1.Testedpump’shydraulic poweratBEPDimensionlessAccountsfordifferencesinpumpefficienciesbetweenmodels.Hassimilarratedvaluesforpumpsofdifferentsizes.LowerPERratingforsmallerpumpsbecauselowercapacityequipmentisinherentlylessefficient.15DeterminingPumpInputPowerPowerinputtothepumpataspecificloadpoint(Pini)canbe:(A) measuredusingawiretowatertest;or(B) calculatedasthepowerinputtothepump(Pi)plusthemotorlossesatthatloadpoint:Where:•Pini=powerinputtothe“pump”atthedriver,inclusiveofthecontrolsifpresent(hp);•Pi=theshaftinputpowertothebareshaftpump(hp);•Li=thefractionalloadmotorlosses(hp);and•i=Percentageofflowatthebestefficiencypoint(BEP)ofthepump.ExpandingthePERequationyieldsthefollowingequation:ܲ௜௡௜ܲ ൌ௜ܮ ൅௜ܨܥܮ ൌ ܴܧܲ∑߱௜ܲ௜ܮ ൅௜௜ݎ݋ݐ݉݅݊ܽ݋݁݊ܦ16TestingBarePumpPerformancePerformHI40.6todeterminebareshaftinputpowerateachloadpointi:•7pointssweptfromshutofftomaximumflowrate,withflowrate(GPM),Head(ft),rotationalspeed(rpm),torque(in‐lbf)recordedinfollowingtable•Hydraulicpumpefficiencyiscalculatedateachflowpoint–Inputpower=(torque)x(speed)–Outputpower=(flowrate)x(head)x(specificweightoffluid)–Efficiency=outputpower/inputpower•BEPfoundbydeterminingmaximumofbestfitcurveofefficiencywithrespecttoflowrate•Bareshaftinputpowerateachloadpointfoundbyinterpolatingperformancefrompumpcurveat75%and110%ofBEPflow%ofBEPflowFlowRate(GPM) Head(ft)Speed(RPM)Torque(lb‐in)HydraulicPower(hp)Shaftinputpower(hp)η(%)η[bestfit](%)128 1200.59 141.51 1774.10 1977.14 41.76 55.65 75.04 74.42108 1012.80 157.91 1774.63 1782.87 39.31 50.20 78.31 77.57100 939.62 162.58 1774.80 1721.36 37.55 48.47 77.47 77.8691 851.24 169.44 1775.86 1613.80 35.46 45.47 77.97 77.6576 709.87 178.40 1775.85 1458.85 31.13 41.11 75.73 75.9658 547.19 186.61 1777.84 1251.15 25.10 35.29 71.12 71.2248 449.06 189.67 1778.80 1112.42 20.94 31.40 66.69 66.1817×standardizedmotorefficiencyanddefaultpartloadcurveMOTORpumpperformancedatafrompumptestatratedspeedDeterminingBarePumpPER×standardizedcontrolsperformance=1Controls•Pivaluesarethetestedshaftinputpowertothepump(speedxtorque)ateachloadpointi•i=75%,100%,and110%offlowrateatBEPofthepump•Equalweighting•StandardizedMotorPerformance•EnclosedmotorthatisminimallycompliantwithDOE’smotorregulations(10CFR431.25)forgeneralpurposemotors(subtypeI)forallpumpsexceptESCCandgeneralpurposemotors(subtypeII)forESCCpumps•HPusedwillbenextHPabovebrakehorsepowerat120%ofBEPHP•Poleswillbebasedonspeedatwhichpumpisbeingrated•StandardizedControlsPerformance•LCF=1(nocontrols)•Driveefficiency=100%(sincenodrive)18×manufacturermotorefficiencyatfullandpartloadMOTORBarePump+MotorTestProcedureManufacturercanpairitspumpdatawithmanufacturermotordata.pumpperformancedatafrompumptestatratedspeedstandardizedcontrolsperformance=1Controls×MOTORPUMPManufacturercanmeasurepowerofpump+motorcombo.standardizedcontrolsperformance=1Controls×pump+motor performancedataAB19pumpperformancefrompumptestatratedandreducedspeed×motor/driveperformancedataBCVFDMOTORControlsMOTORPUMPBarePump+Motor+ControlsTestProcedureManufacturercanpairitspumpdatawithtestedmotor+VFD data.Manufacturercanmeasurepowerofpump+motor+controlscombo.×manufacturerordefaultmotorefficiencyAMOTORManufacturercanpairitspumpdatawithmanufacturermotordataanddefaultfactorforcontrols.pumpperformancedatafrompumptestatratedspeeddefaultcontrolsperformanceControls×20LoadControlFactor:BasisLCFisdefinedastheratioofPERofaspeedcontrolledpumptothePERofanuncontrolledpump•ܨܥܮ ൌ௉ாோ಴೚೙೟ೝ೚೗೗೐೏௉ாோೆ೙೎೚೙೟ೝ೚೗೗೐೏•LoadcontrolfactorfortheVFDprovidedinPERcalculationexamplevariesdependingonloadprofileandweightingPERofpump+motor willbeusedtodeterminetheLCFforeachcontroloptionUseanassumedconservativesystemcurveforallthreeoptionswithfollowingvariationstodeterminetheLoadControlFactorAssumptions:•Efficiencyofcontrol=96%ࡽ૚ࡽ૛ൌ࢔૚࢔૛ࡴ૚ࡴ૛ൌ࢔૚࢔૛૛ࡼ૚ࡼ૛ൌ࢔૚࢔૛૜21LoadControlFactorOptions•Othercontroloptionstobeconsidered?•MakeLCFafunctionofefficiencytodistinguishsimilarcontroloptionswithdifferentefficiencies?ControlEfficiencyofControlOtherAssumptions LCFVFD 96% Followdefined systemcurve 0.56ECM 96% 0.602‐speed motor 96%25% and50%loadpointareatlowerspeed&75%and100%loadpointsareatfullspeed0.6722OptionsforDeterminingPERFLforaControlledPumpܨܥܮ ൌ ܴܧܲ߱଴.଻ହܲ௜௡଴.଻ହ൅ ߱஻ா௉ܲ௜௡஻ா௉൅ ߱ଵ.ଵܲ௜௡ଵ.ଵܴܧܲ௡௜௠ൌ1η௖௧௥௟߱଴.ଶହܲ௜௡଴.ଶହ൅ ߱଴.ହ଴ܲ௜௡଴.ହ଴൅ ߱଴.଻ହܲ௜௡଴.଻ହ൅ ߱஻ா௉ܲ௜௡஻ா௉߱଴.଻ହܲு௬ௗ௥௢,଴.଻ହ0.95 ∗ ߟ௣௨௠௣൅ ܮ଴.଻ହ൅ ߱஻ா௉ܲு௬ௗ௥௢,஻ா௉ߟ௣௨௠௣൅ ܮ஻ா௉൅ ߱ଵ.ଵܲு௬ௗ௥௢,ଵ.ଵ0.985 ∗ ߟ௣௨௠௣൅ ܮଵ.ଵLCFApproach FullCalculationApproachPumpPerformancePi=measuredshaftinputpowertothepump(speedxtorque)ateachloadpointiWhere:i = 75%,100%,and110%offlowrateatBEPofthepumpandequalweightingPi=calculatedshaftinputpowertothepumpbased onaffinitylawsateachloadpointiWhere:i =25%,50%,75%,and100%offlowrateatBEPofthepumpandequalweightingMotorPerformance(Losses)LratedisthefullloadlossesofamotorthatispairedwiththepumpandlossesarecalculatedforthereducedloadingwithspeedreductionControlsPerformanceLCF=0.56forVFDcontrol,0.67for2‐speedmotor,etc.Accountsforreducedpowerinputatloadpointsof25%,50%,75%and100%ofBEPflowDriveefficiency=96%Benefitiscapturedincalculation ofbareshaftinputpower.Couldstillaccountfordriveefficiency.