# INTRODUCTION **AND INSTRUCTIONS**

Thank you very much for participating in the extra data collection efforts in support of DOE's negotiated rulemaking for pumps. In the following tabs you will find requests for a variety of information related to circulators. will support our efforts to directly address the inquiries of the pumps rulemaking working group. We will treat this data as confidential under the terms of the NDAs on file with Navigant and LBNL. **Timeline: The deadline**  **for submission is Friday, January**  **17, end of day.** 

We realize this is a very short timeline, but we are hoping to be able to aggregate data in advance of the next stakeholder meeting on January 30 in order to help stakeholders negotiate rulemaking scope. **Priority:** Ideally we would like you to answer all of the questions as accurately as possible. But

realistically we understand that accurate estimates may not be available within the requested one turnaround. That said, please address all questions as best you can, **but give priority to the tabs**  **highlighted in green**  and ensure that you can provide accurate responses to those questions.
**Format** : If you don't feel you can provide the data in the format we have suggested here, please contact to discuss alternative formats. **Clarity:** If you have any questions at all regarding the clarity or intent of a survey question, please do not

hesitate to call Navigant. Contact info is: Daniel Weintraub Navigant Email: daniel.weintraub@navigant.com Office: 781

- 270

-8397 Cell: 516

-849

- 6100

## Thank you very much for participating in the extra data collection efforts in support of DOE's negotiated rulemaking variety of information related to circulators. This data directly address the inquiries of the pumps rulemaking working group. We will treat this data as confidential under the terms of the NDAs on file with Navigant and LBNL.

We realize this is a very short timeline, but we are hoping to be able to aggregate data in advance of the next stakeholder meeting on January 30 in order to help stakeholders negotiate rulemaking scope. we would like you to answer all of the questions as accurately as possible. But realistically we understand that accurate estimates may not be available within the requested one

-week **but give priority to the tabs**  and ensure that you can provide accurate responses to those questions. If you don't feel you can provide the data in the format we have suggested here, please contact us
the clarity or intent of a survey question, please do notQuestion 1, Table 1
**List all Circulators 1/25 to < 3 HP 2013**  **2012 2011**  **2013 2012**  **2011**

**Model Name Housing**  **Material Rotor Type:** 

**[Wet/Dry] Motor Type:** 

**[ECM/AC] Speeds and Controls** 

**[See dropdown and definitions**

**below] Circulator** 

**Classification*** **Nameplate**

**HP Max Rated** 

**Electrical Power Draw to Motor**  **(Watts) Rated Electrical** 

**Power Draw at Middle Selectable**  **Speed or Median of Speed Range**  **(Watts) Rated Electrical** 

**Power Draw at Minimum**  **Selectable Speed (Watts)**  Example: ABC 1001 Cast Iron Wet AC Single Speed - No Control CP1 1/25 85 77 60

**$0.00 $0.00**  **$0.00 0**  **0 0**  Please add lines as necessary **Survey on Shipments: 1/25 to < 3 HP Pumps**

**Net Sales $ Volume**
NOTE: This represents total revenues from sales to United States distributors or any other direct United States customers, including OEM products for use in the USA. **Unit Volume** NOTE: This represents total revenues from sales to United States distributors or any other direct United States customers, including OEM products for use in the USA. For Multi-Speed - Manual Circulators Only

## New Product Introductions

2. The survey on the first tab only considers shipments up to December 31, 2013. Please provide any relevant information on energy efficient circulators that are planned for introduction in the next two years. Please feel free to attach separate files, or provide data in whatever format is most convenient.

3. How do you expect the market penetration of high efficiency circulators to change over the next 5 years? - Please discuss this only in terms of your own company's market share. - Please provide estimates of predicted trends for ECM sales, as a percentage of your total sales, if available.

## Survey on Load Profiles

The following questions are to help better understand representative load profiles for the US circulator market. Such profiles will be used to aid in the calculation of annual energy consumption and potential **4. Constant Speed Circulators** 4a. For **Heating Applications:** In the United States, how many hours per year do you believe the average constant speed circulator runs? - Please p rovide your answer in terms of days/year of system operation and hours/day of system and or zone operation.

4b. For **Potable Water Applications:** In the United States, how many hours per year do you believe the average constant speed circulator runs? - Please p rovide your answer in terms of days/year of system operation and hours/day of system and or zone operation.

4c. While operating at a point lower than max flow, do you believe a standard AC single speed circulator draws significantly lower power (watts) than max rated power draw (watts)? If so, what percent of rated motor power draw do you estimate the average circulator runs at? This question is based on the understanding that the intersection of the system curve and pump curve defines the actual electrical power draw (watts).

**5. Multi-Speed - Manual User-Selected Control** 5a. For Multi-Speed - Manual circulators, what do you estimate as the average speed setting that your products are run at? Please provide a weighted average between 1 and 3, using the following parameters: Max Speed = 3.0 Mid Speed = 2.0 Min Speed = 1.0 For Example: Pumps run at max speed 90% of the time, mid speed 7% of the time, and min speed 3% of the time. (90% x 3.0)+(7% x 2.0)+(3% x 1.0) = 

### 2.9 Please do not include time spend at zero speed or off.

**6. Variable Speed Circulators**6a. Given the differences between the European and North American circulator markets and applications, do

you feel that the EU Lot 11 load profile (Blauer Engel) for circulators applies to the US market? Please explain **Blauer Engel / EU Lot 11 Load Profile for System operation:** 6% time at design load (max) 15% time at 75% design flow 35% time at 50% design flow 44% time at 25% design flow

6b. If no, please elaborate on a load profile that might best represent the US market in calculations used to estimate national energy usage and potential energy savings. If possible, please different iate between **Heating** and **Potable Water** applications.

6c. Given your variable speed load profile of choice, Blauer Engel or otherwise, do you believe that variable speed circulators run more hours per year than a single speed circulator? (This question is based on the premise that a modulated variable speed system may run more hours at lower7b. Larger than 100 watts 

## Survey on ECM Availability

Please answer for the follow two HP groupings: Do you have sufficient manufacturing resources* or sufficient external supply** to meet your company's full scale*** ECM production needs by the start of 2015? Do you envision there being sufficient manufacturing resources and/or external supply by 2020? *Manufacturing resources include but are not limited to: production infrastructure, trained personnel, and manufacturing components (including magnets). **External supply refers to complete ECMs that meet your specs, and are available to be purchased and shipped to your factory. *** Full scale means that all of your current circulator shipment would require ECM. 

### The following questions are to help better characterize the availability of ECM suitable for use in the circulator market 7. Suppose that a potential DOE regulation effectively required ECM on all circulators (CP1, CP2 and CP3).

7a. 100 watts and smallerDo you have sufficient manufacturing resources* or sufficient external supply** to meet your company's full scale*** ECM production needs by the start of 2015?

*Manufacturing resources include but are not limited to: production infrastructure, trained personnel, and manufacturing components (including magnets). **External supply refers to complete ECMs that meet your specs, and are available to be purchased and shipped to your factory. 

### The following questions are to help better characterize the availability of ECM suitable for use in the circulator market**Table 8a**

**Column 1 Column 2**  **Column 3 Column 4**  **Column 5**
**Nameplate HP [1/25 to 3 HP]**  **AC MOTOR** 

**Max Rated Electrical Power Draw (Watts)**  **Single Speed AC Motor Cost ($)**  **Three Speed AC**

**Motor Cost ($)** [If Applicable] **Current Pricing**

**ECM Cost ($)** [Replacement for the motor in Column 2]

**Table 8b Column 1**  **Column 2 Column 3**  **Column 4 Column 5**  8. In the tables below, please provide comparative manufacturing or purchasing costs for ECM vs. traditional circulator AC motors. Three tables have been provided, corresponding to CP1, CP2, and CP3 product types. **Please provide the ECM costs under two assumptions:** - Column 5: Current unit motor cost -- This is the 2014 per-unit cost to either manufacture or purchase from an outside supplier. - Column 6: Economies of scale -- This is an estimate of the 2020 per-unit cost to either manufacture or purchase from an outside supplier, under the assumption that ECMs are to be sold at volumes similar to the current AC motors. **NOTES:** - AC Motor Cost for CP1 includes cost both of the stator and the rotor. - Cost should represent either the actual/estimated cost to manufacture internally or purchase from an outside supplier. - In the space to the right of the table please comment on which motor types and sizes you currently make/buy and which sizes and types plan to make/buy in 2020. - ECM costs should include the cost of the integrated motor controller and the additional logic controller. - Assume that all products will be sold with logic and "smart controls." - Because ECM do not come in "standardized" increments and can cover a larger hydraulic range than AC motors, please provide the cost of a motor that would replace the AC motor size specified in column 2. Please specify this ECM wattage in Column 7. 

## CP1 ONLY

**CP2 ONLY Survey on ECM Cost**  The following questions are to help better characterize the costs of ECM suitable for use in the circulator market**Nameplate HP**

**[1/25 to 3 HP] AC**  **MOTOR**

**Max Rated Electrical Power Draw (Watts)**  **Single Speed AC Motor Cost ($)**  **Three Speed AC**

**Motor Cost ($)** [If Applicable] **Current Pricing**

**ECM Cost ($)** [Replacement for the motor in Column 2]

**Table 8c Column 1**  **Column 2 Column 3**  **Column 4 Column 5** 
**Nameplate HP [1/25 to 3 HP]**  **AC MOTOR** 

**Max Rated Electrical Power Draw (Watts)**  **Single Speed AC Motor Cost ($)**  **Three Speed AC**

**Motor Cost ($)** [If Applicable] **Current Pricing**

**ECM Cost ($)** [Replacement for the motor in Column 2] 

## CP3 ONLY**Make vs. Buy**

**Column 6 Column 7**  **2020 Economies of Scale**  **ECM Cost ($)** [Replacement for the motor in Column 2] **REPLACEMENT ECM**

**Max Rated Electrical Power Draw (Watts)** 

**Make vs. Buy Column 6**  **Column 7** 8. In the tables below, please provide comparative manufacturing or purchasing costs for ECM vs. traditional circulator AC motors. Three tables have been provided, corresponding to CP1, CP2, and CP3 product types.
- Column 5: Current unit motor cost -- This is the 2014 per-unit cost to either manufacture or purchase from an outside supplier. - Column 6: Economies of scale -- This is an estimate of the 2020 per-unit cost to either manufacture or purchase from an outside supplier, under the assumption that ECMs are to be sold at volumes similar to the current

- Cost should represent either the actual/estimated cost to manufacture internally or purchase from an outside supplier. - In the space to the right of the table please comment on which motor types and sizes you currently make/buy and which sizes and types plan to make/buy in 2020.
- Because ECM do not come in "standardized" increments and can cover a larger hydraulic range than AC motors, please provide the cost of a motor that would replace the AC motor size specified in column 2. Please

**Please comment below on sizes/types you currently make/buy and which sizes and types plan to make/buy in**  **2020.** 

### The following questions are to help better characterize the costs of ECM suitable for use in the circulator market**2020 Economies of**

**Scale ECM Cost ($)**  [Replacement for the motor in Column 2] **REPLACEMENT ECM**

**Max Rated Electrical Power Draw (Watts)** 

**Make vs. Buy Column 6**  **Column 7 2020 Economies of**  **Scale ECM Cost ($)**  [Replacement for the motor in Column 2] **REPLACEMENT ECM**

**Max Rated Electrical Power Draw (Watts)**  **Please comment below on sizes/types you currently**

**make/buy and which sizes and types plan to make/buy in 2020.** 

**Please comment below on sizes/types you currently make/buy and which sizes and types plan to make/buy in**  **2020.**$0.00 $0.00

$0.00 $0.00 10. Please provide details on what product types or models would be discontinued, rather than redesigned. Sub Totals Marketing Sub Totals



## Pump Size: 1 HP [These costs should be representative of larger, lower volume circulators] Pattern, Tooling Number of ECM Families **≤ 1/4 HP**to be developed **TOTAL REDESIGN COST TO MANUFACTURER**

Number of ECM Families **> 1/4 HP**to be developed **TOTAL REDESIGN COST TO MANUFACTURER** Marketing 

## Survey on the Cost of Circulator Design 9. In the tables below, please provide quantitative detail on the costs required to redesign from an AC motor driven circulator to an ECM driven circulator with the most efficient available hydraulic design. We are interested in two specific sizes ranges, 1/4 HP and 1 HP. **Please note the following:** - Assume you are designing for introduction by year 2020. - Assume that your tooling costs must satisfy production volumes equal to your current AC motor sales. - We are interested in the cost to design one FAMILY of circulators. - FAMILY is defined as a group of similar sized circulators that would be designed together in one effort, under one budget. - Because each manufacturer's functional definition of FAMILY may be different, we ask that you specify the number of FAMILIES that would be designed if ECM were to be required on all circulators. - This number may be lower than your current number of AC motor families. - Multiplying number of families by your per-family design cost should give us a rough indication of the total cost of redesign for your company. - We understand that not all current models would be carried over to ECM. If you currently manufacture a certain class of circulator, but would not plan to redesign it for ECM, please leave column blank and provide details in question 10 below. - Please use the legend provided to the right to define each term.

Redesign, Prototype & Initial Test



## Pump Size: 1/4 HP [These costs should be representative of smaller, higher volume circulators] **CP1**

Working Capital Final Testing Pattern, Tooling **Redesign Cost for one Circulator FAMILY**

**Redesign Cost for one Circulator FAMILY Table 9a** 

**Table 9b**

Redesign, Prototype & Initial Test **CP1**

Final Testing Working Capital12b. We understand that some product families may already be redesigned, but are not prepared for high volume manufacturing. Please estimate

the aggregate additional tooling and infrastructure costs that you believe are necessary to bring these product families up to high volume by 2020. Only specify unique costs not covered in Question 9. How many product families are included in these costs?

13. How would you expect to recover these expenses? - Margin increases to all product offerings (circs and larger pumps) - Margin increases to all circulator offerings only - Margin increases to redesigned products only - No Margin increases -- absorb costs internally - Other (please elaborate) 11. Do your costs represent internal manufacturing or external sourcing of ECM?

12. Tooling Costs -- 12a. We understand that production infrastructure may be shared across multiple circulator product families. If multiple product families were to require redesign, can we directly scale up your tooling costs, or do these costs cover multiple product families?$0.00 $0.00

$0.00 $0.00

$0.00 $0.00 $0.00 $0.00 10. Please provide details on what product types or models would be discontinued, rather than redesigned. 9. In the tables below, please provide quantitative detail on the costs required to redesign from an AC motor driven circulator to an ECM driven circulator with the most efficient available hydraulic design. We are interested in two specific sizes ranges, 1/4 HP and 1 HP.
- Assume that your tooling costs must satisfy production volumes equal to your current AC motor sales. - FAMILY is defined as a group of similar sized circulators that would be designed together in one effort, under one budget. - Because each manufacturer's functional definition of FAMILY may be different, we ask that you specify the number of FAMILIES that would be
- Multiplying number of families by your per-family design cost should give us a rough indication of the total cost of redesign for your company. - We understand that not all current models would be carried over to ECM. If you currently manufacture a certain class of circulator, but would not plan to redesign it for ECM, please leave column blank and provide details in question 10 below.

**CP3 CP2**  **Redesign Cost for one Circulator FAMILY**

**Redesign Cost for one Circulator FAMILY**

**CP2 CP3** 12b. We understand that some product families may already be redesigned, but are not prepared for high volume manufacturing. Please estimate the aggregate additional tooling and infrastructure costs that you believe are necessary to bring these product families up to high volume by 2020. 12a. We understand that production infrastructure may be shared across multiple circulator product families. If multiple product families were to require redesign, can we directly scale up your tooling costs, or do these costs cover multiple product families?

## LEGEND

Design Process Factor Descriptions

**Design Costs :**  Hydraulic Design, Mechanical Design, Electrical and Motor Design, Controller Design, Simulation, Prototype Development, Prototype Tooling, Initial Testing **Pattern & Tooling Costs:** Supplier Development, Patterns, Tooling (Machine Fixtures, Assembly Fixtures, Test Fixtures). Machine Programming, Quality Inspection (Parts, Tooling), New Process Development (Casting and/or Machine Processes), New Machine Tools, Retraining. **Testing:** Performance (All Speeds), Hydrostatic, Certification Testing, Field Beta Testing Production Documentation, Training, etc. **Working Capital:** Cost of money to finance upgrades, Inventory (Cost, Rework Transition, Inventory for legacy support.) **Marketing:** Literature, Data Sheets, Curves, Pump Selection Tools, Sales Training, Compliance Documentation, etc.

## Survey on Circulator Testing Costs

The following questions are to help better characterize the capital and per-unit costs associated with testing circulators, in the presence of an energy conservation standard. 14. Do you currently use ISO9906 as the test method to develop published circulator performance data for end users? If not, please describe how your methods differ, or attach any relevant performance verification testing methodology.

15. Assuming a certified test procedure requires data such as head, flow, power consumption, and line to water efficiency at various load profiles and various system curves, please describe the additional one time investment costs (conversion costs) needed to setup facilities to adequately test circulators for certification. - Please assume accuracy limits similar to those set forth in the EU Lot 11 circulators test procedure. Relevant accuracy parameters are listed in the cell below. - Please consider the aggregate cost to establish facilities capable of testing all circulator HP ranges for CP1, CP2, CP3. - Please account only for costs needed to go beyond your current testing capabilities. - Please provide an estimated dollar value as well as a description of what these costs represent. Relevant Accuracy Parameters: - Ambient temperature held to +/- 5 oC - Static system pressure of 2 Bar. (Tolerance of +.5bar/-0bar) - Nominal motor input voltage held within ±1% of nominal - For tolerance on Q/H load curve points -- Maximum permissible distance between H 100%and published curve: For motors ≤ 100 W: +/-20% For motors > 100 W: +/-10% - Although there are more parameters, please consider these at this time.

15b. Have the costs in 15a been included in your cost of Cost of Product Development numbers specified in the previous tab?

16. What is the estimated cost to test and certify each model to a DOE standard? - For the purposes of this analysis, a model is defined as a unique combination of electrical and hydraulic designs. For example, identical pumps with different flange fittings need not be tested separately. - For certification, the model only needs to be tested once. Once certified, individual production units need not be tested.

17. How many models do you anticipate having to certify?18. If you feel that the accuracy limits and equipment requirements of the EU Lot 11 test procedure is

inappropriate for the US market, please provide details on a test procedure you support. In addition please