Building Bridges to Net Zero Adjustable Speed Motor and VFD Applications and Opportunities in Multifamily Buildings

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1 Building Bridges to Net Zero Adjustable Speed Motor and VFD Applications and Opportunities in Multifamily Buildings Andrew Brooks Nick Dirr

2 Types of Motors: AC Induction Motor Permanent Magnet AC Motor DC Brushless ECM Motor Motors 2

3 3

4 AC Induction Motors 90% of motors in the United States Cheap, relatively low maintenance, reliable Consists of two parts: the stator (stationary), and the rotar (rotating). The rotar is spun using induced magnetic fields in the stator. 4

5 DC Brushless Electronically Commutated Motor (ECM): Most efficient Higher cost (permanent magnets) No physical commutator (brushes) means: less upkeep on the motor less friction losses higher motor speeds longer motor life higher efficiency Compatible with variable speed controls (often combined package with pump/fan and the motor) Better efficiency % efficient at all speeds as compared to PSC which is 50-60% efficient (lower at reduced speeds) Typically smaller and lighter when compared to a AC motor of similar HP High torque at low speed compared to AC motors 7

6 Savings Opportunities Motors According to the US Department of Energy, electric motordriven equipment is responsible for 25% of all energy use in the United States. Cost of operating a motor can often be more than the cost of replacing with a more efficient motor, especially if motor is oversized for loads. Where to look in multifamily: circulators, pumps, fans, elevators 8

7 Multifamily Motor Examples Rooftop Exhaust Fans 9

8 CW Booster Pumps DHW Boiler Pump Large Central Air Handler DHW Recirculation Exhaust Fans Exhaust Fans 10

9 Multifamily Motor Examples Hot Water Heating System Circulators Chillers and Cooling Towers 11

10 Multifamily Motor Examples Elevators Elevator Motor-Generator Sets 12

11 Motors Benefits of VFD or Adjustable Speed Motor Retrofits: Greater energy efficiency More precise control (air flow, water flow, speed, etc.) Soft-starting and stopping of motors to prolong pump/fan life Integration of Building Management System (BMS) communication Allows operator to easily adjust system flow if it gets out of balance or experiences reduced Delta T 13

12 AFFINITY LAWS 14

13 Law 1: Flow is proportional to shaft speed Law 2: Pressure or head is proportional to the square of the shaft speed Law 3: Power is proportional to the cube of shaft speed 15

14 Fan Laws Proportional Relationship CFM(new) = RPM(new)/ RPM(old) x CFM(old) Square Relationship SP(new) = (RPM(new)/RPM(old)) 2 x SP(old) Cube Relationship BHP(new) = (RPM(new)/RPM(old)) 3 x BHP(old) 16

15 Pump Affinity Laws Proportional Relationship GPM(new) = RPM(new)/ RPM(old) x GPM(old) Square Relationship Ft of Head(new) = (RPM(new)/RPM(old)) 2 x Ft of Head(old) Cube Relationship HP(new) = (RPM(new)/RPM(old)) 3 x HP(old) 17

16 FANS 18

17 Belt Driven Fixed Speed Fans 19

18 Belt and sheave alignment issues Warn out belts 20

19 Replacement of fan and/or motor sheave, and the belt Downsides: Should be done by T&B ($) Still stuck with a single speed fan Replace with properly sized smaller fans 21

20 Better Solution = Direct Drive Adjustable Speed Fans 22

21 Before 23

22 After 24

23 Direct Drive Adjustable Speed Fans Advantages No belts to break, wear down and change No sheave problems Allows for precise speed control without mechanical alterations (you can do it yourself) Can use ECM s 80% turndown ratio (from 100% - 20%) vs. standard PSC motor speed controls 30% (from 100% - 70% ) 25

24 Variable Frequency Drives If fans are new, and you do not want to replace it, may be cost affective to install VFD s Many operating at same rate allows for multiple fans on a single VFD Accepts input signals for continuous speed control 26

25 Savings Potential 27

26 Savings Calculation Example 10-story building with 12 central bathroom exhaust shafts Originally designed at 50 CFM/bathroom You propose reducing ventilation rates to 25 CFM/ bathroom Total reduction of 250 CFM/shaft 250 * 12 shafts = 3000 CFM net reduction 28

27 Savings Calculation Example (cont.) 29

28 Savings Potential Cost of Ventilation (electrical) VC = FP D T K.001 VC = annual electricity cost of ventilation FP = fan power in watts T = hours per day fan operates D = days per year fan operates K = the cost per kwh.001 is to get you from $/kwh to $/watt 30

29 Savings Calculation Example (cont.) $

30 Pumps 32

31 Pump Affinity Laws P = Motor Power to Operate Pump RPM = Impellor Speed (Pump Speed) Remember that RPM is directly proportional to flow (GPM) Energy use changes by the cube of the speed change P(new) = (RPM(new)/RPM(old)) 3 x P(old) Decreasing speed or flow by ½ will reduce power consumption to 1/8 of initial power

32 Example #1 A 5 HP or 3,750 Watt pump, operating at 3,500 RPM, circulates 80 GPM of water Reducing the speed of the pump by 50%, to 1,750 RPM and 40 GPM of water, reduces the pump power by 87.5% of previous, or down to HP or 470 Watts Example #2 What the heck are you talking about?!? Give me an example A 3 HP or ~2,250 Watt pump, operating at 3,500 RPM, circulates 60 GPM of water Reducing the speed of the pump by 20%, to 2,800 RPM and 48 GPM of water, reduces the pump power by 49% of previous, or down to 1.54 HP or 1,150 Watts For a pump providing heating hot water for a third of the year, that is 3,200 kwh or $480/yr in savings. 34

33 Get Pump Nameplate Data Pump Nameplate Motor Nameplate 35

34 Why is variable speed pump better than single speed pump? With single speed pump, we may end up riding the curve as zones close What does riding the pump curve mean? Operating at an inefficient pump set point with potential to damage the pump How can variable speed pumps help save energy? Understanding Pump Affinity Laws to maximize efficiency when there is reduced demand 36

35 Zone and Space Temperature Controls TRVs Electric zone valves (solenoid valves) controlled by thermostat 37

36 TRV s allow for use of high efficiency variable speed circulators 38

37 Multifamily Motor Examples Single Speed Hot Water Heating System Circulators Oakland, CA 39

38 Packaged System Vs. Component System OR 40

39 Cold Water Pumps: Before Pumped System: Usually found in taller buildings. Single speed pumps. Pressure restricted with Pressure Reducing Valves (PRV s) Opportunity for VFD s. 41

40 Multifamily Motor Examples BEFORE: Single Speed CW Booster Pumps AFTER: VFD CW Booster Pumps 42

41 Cold Water Pumps: After Varies the speed of the pumps to maintain set pressure iin the pipes Typical target pressure is psi for larger buildings 43

42 Multifamily Motor Examples Variable Speed CW Booster Pumps 44

43 ELEVATORS 45

44 Savings Opportunities Elevators If owner is planning to upgrade, work with elevator consultant to influence installation of more efficient equipment. Motor Generator Sets (MG Sets) High power consumption: The combined efficiency of a motor and generator working together to generate DC power is poor. Additionally, an MG set creates a constant and significant power drain -- even at idle speed when the elevator is not in motion (35% to 45% of full load current). Excessive generator brush wear: Brush wear is a continuing and serious problem. Additionally, the large amount of carbon dust generated can contaminate the machine room, frequently causing failure of other electrical equipment. Replace w/ SCR Controls or AC VVVF (variable-voltage, variable-frequency) drive If not part of an overall system upgrade it is generally NOT cost effective. 46

45 Elevators Motor-Generator Sets 47

46 Elevators AC Motor Variable Speed Drive and Modern Controls 48

47 Importance of Commissioning If you are not 100% sure that it is going to be commissioned properly, don t bother installing it in the first place Need to be able to confirm that the speed of the motor is reacting to system feedback and controls. Just putting a box on the wall that says VFD control does not mean any energy will be saved. 49

48 Andy Brooks Director of West Coast Operations Nick Dirr Director of Multifamily Technical Services 50

49 Parking Lot 51

50 FAN/PUMP CURVES 52

51 Fan Terminology Static Pressure, SP: The measure of the potential energy of the airstream. SP acts equally in all directions. It is the pressure in the duct that tends to burst or collapse the duct. Velocity Pressure, VP: The measure of the energy content of the airstream. VP acts in the direction of airflow. The pressure necessary to accelerate the air. Total Pressure, TP: The measure of the energy content of the airstream. It is the sum of the static pressure and the velocity pressure. 53

52 Fan Curves & System Curves Fan static pressure curve is the basis of all airflow and pressure calculations Fan Curve Graphical representation of the relationship between the quantity of air a fan will deliver and the pressure generated at various air quantities System Curve Graphical representation of the sum of all pressure losses in a duct system 54

53 System Resistance Curves The only time the shape of the system resistance curve changes is when the system physically changes. Ductwork Elbows Transitions Filters Coils Dampers Louvers Building Pressure For instance, if a damper is opened, the system resistance is reduced. The result is a lower pressure drop. 55

54 Varying System Resistance Curve Going from curve A to curve B would be an example of a system that gets clogged up with dirt over time. 56

55 Fan Curve plotted against system curve Fan Performance Operating Point Brake Horsepower System Resistance 57

56 Cube Relationship BHP(new) = (RPM(new)/RPM(old)) 3 x BHP(old) 58

57 Fan Curve plotted against system curve with VFD Fan Performance Operating Point Brake Horsepower System Resistance 59

58 Resources Motormaster NEMA Contact us Nick Dirr Andrew Brooks 60

2

2 Brushless DC motors 2 3 VFD VS ECM(PM Motors) Both take AC and convert to DC VFD is generally 3Ø ECM 1Ø in 3Ø out VFD & ECM Both have Rectifiers VFD & ECM both have transistor outputs VFD Out put

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