Fan Industry: Facing Up to the Energy Challenges
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1 Fan Industry: Facing Up to the Energy Challenges AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL, INC. Dr. Michael Brendel Vice President, Engineering and Marketing Lau Industries / Ruskin Company Dayton, OH USA Franco Cincotti Director, Engineering Comefri USA Hopkinsville, KY USA
2 Session Topics Part 1 - Overview of HVAC Energy Issues HVAC System Energy Consumption HVAC System Energy Metrics Fan Efficiency Metrics - FEG and FMEG Part 2 - Draft Standard and Examples Draft AMCA 205 Fan Selection Implications/Examples Questions/Discussion
3 Energy Consumption 2008 Estimated US Energy Consumption 1 99 Quads (I05 EJ) 1 LLNL / DOE / EIA 2009
4 Energy Consumption LLNL / DOE / EIA 2009
5 Energy Consumption - HVAC Systems Estimated US HVAC Energy Consumption Quads (1.5 EJ) Fans + Pumps 1.9 Quads (2.0 EJ) Heating 1.9 Quads (2.0 EJ) Cooling 2 DOE source energy
6 HVAC System 1) volumetric flowrate (design requirement) Control Damper Diffuser Intake Louver Ductwork Terminal FAN Filter Coil Balance Damper 2) system resistance (design result)
7 HVAC System FAN + P v P t _ P s P t always decreases in absence of energy input
8 System Energy Metrics Total Energy = Kinetic Energy + Potential Energy P t Q= P v Q+ P s Q = flow (air) power (H o ) Energy rate to maintain air motion Energy rate to overcome resistance
9 System Energy Metrics Electricity Generation (Source) Shaft Power (H sh ) Motor Drive Fan Motor/Controls Input Power (H dc ) Site Energy Rate Flow (air) Power (H o )
10 System Energy Metrics - Example 25 Belt Drive Airfoil DWDI Blower Motor - 90% efficient, Drive - 90% efficient Operating point: 16, in-wg (total) Motor Output Power ( W, 90%) Shaft Power (13,246 W, 65%) Aerodynamic Loss (3,260 W,16%) Fan Bearing Loss (815 W,4%) Motor Input Power (20,378 W, 100%) Motor Drive Fan Flow Power (12,838 W, 63%) Motor Loss (2,038 W, 10%) Drive Loss (1,834 W, 9%) Acoustic Loss (80 db 0.1 mw, <<1%)
11 System Energy Metrics - Example 25 Direct Drive Plenum Fan Motor - 90% efficient, No Drive Operating point: in-wg (total) Shaft (Impeller) Power (9,139 W, 90%) Aerodynamic Loss (2,335 W, 23%) Motor Input Power (10,154 W, 100%) Motor Fan Flow Power (6,905 W, 68%) Motor Loss (1,015W, 10%) Acoustic Loss (80 db 0.1 mw, <<1%)
12 System Energy Metrics How do we reduced HVAC (airside) energy consumption? Flow resistance (system design) Minimum duct resistance Low pressure drop components (coils, filter, dampers) min {P t Q} Flowrate (application requirement) Minimum Q to achieve HVAC goal Minimize system leakage
13 System Energy Metrics One approach Specific Fan Power (SFP) Fan Input Power SFP = Flowrate H dc Q
14 System Energy Metrics Specific Fan Power (SFP) Input Power H SFP = dc = Q Required Flowrate System Total Pressure P t η dc Input Power Air Power Efficiency
15 System Energy Metrics Efficiency - including motor, drives, fan: Air Power H η dc o = H dc P t Q H dc Input electrical energy
16 System Energy Metrics η dc - combination of component efficiencies: System resistance SFP = P t η c η m η d η t controls drive motor fan
17 System Energy Metrics Placing upper limit on SFP: Example: If SFP < 700 W/kcfm (0.94 HP/kcfm) Places upper limit on P t = 6 in-wg (1,500 Pa) Pt < 6 in-wg for η dc < 100% Effective means to assure efficient system design
18 System Energy Metrics Reducing Energy Consumption Minimize P t for given flow requirement (SFP) Duct/System designer responsibility Maximize motor/control/drive efficiency (η m, η c, η d ) Motor/Control/drive supplier responsibility Maximize fan efficiency (η t ) Fan manufacturer responsibility Next: Focus on fan efficiency
19 Fan Energy Metrics air energy rate out Fan Efficiency = shaft energy rate in = air power out shaft power in shaft power in H sh air power out H o
20 Fan Energy Metrics Efficiency - fan (without drives): H η t o = H sh P t Q H sh Fan input power
21 Fan Efficiency Proposed Fan Energy Grading Metric Goals Simple to implement Grading system applies to fan model range Provide simple means to compare fan designs Based on total fan energy (total pressure) Provide tool for regulative bodies
22 Fan Efficiency Two Proposed Metrics: Fan Motor Efficiency Grade (FMEG) Input at motor/control electrical mains Suitable for fans sold with integral motorized impeller Based on overall fan efficiency Function of motor/control input power Fan Efficiency Grade (FEG) Input at fan shaft/impeller Suitable for fans sold less drive/motor Based on fan peak total efficiency Accounts for the effects of impeller diameter
23 Fan Efficiency Grades FMEG FEG Motor Drive Fan Typical Belt Drive Fan
24 Fan Efficiency Grades FMEG FEG Motor Fan Typical Direct Drive Fan
25 Fan Efficiency Practical Considerations (FEG) Efficiency varies with fan operating point Peak efficiency varies with Fan type Fan tip speed Fan size
26 Fan Efficiency Effect of impeller diameter for geometrically similar fans at same tip speed Total Efficiency, η t η t - large diameter η t - small diameter Flowrate, Q
27 Fan Efficiency Geometric/Aerodynamic Similarity? Reasonable manufacturing tolerances Low Reynolds number performance degradation Mechanical losses don t follow fan laws
28 Fan Efficiency Source: John Cermak
29 Fan Efficiency 90 Fan Efficiency Grade (FEG) Peak Total Efficiency, pte (%) FEG 85 FEG 80 FEG 75 FEG 71 FEG 67 FEG 63 FEG 60 FEG 56 FEG 53 FEG Impeller Diameter (in)
30 Fan Efficiency Peak Total Efficiency, pte (%) Fan Efficiency Grade (FEG) pte = 67% D = 15 (381 mm) FEG = 75 FEG 85 FEG 80 FEG 75 FEG 71 FEG 67 FEG 63 FEG 60 FEG 56 FEG 53 FEG Impeller Diameter (in)
31 Fan Efficiency Fan Efficiency Grade (FEG) Grade labels in preferred numbers (R40) Reference diameter: 40 in (I0I6 mm) Minimum defined diameter: 5 in (I25 mm) Fans >40 in use reference diameter Grade Formula defined - for electronic calculation Peak Total Efficiency, pte (%) Impeller Diameter (in)
32 Part 2 Draft Standard AMCA 205 & Selection Examples
33 Fan Efficiency Standards Activity DIS/ISO I2759 Fans - Efficiency Classification for Fans AMCA 205 (draft) Energy Efficiency Classification for Fans Fan Efficiency Subcommittee appointed by AMCA Fan Committee - SEP 2008 Draft AMCA 205 approved by the AMCA Fan Efficiency Subcommittee - OCT 2009 Draft AMCA 205 approved by the AMCA Fan Committee - OCT 2009 Draft AMCA 205 out for approval to AMCA Members - DEC 2009 Next Steps: Development of a FEG/FMEG AMCA Certification Program
34 Draft AMCA 205 Fan Efficiency Grade (FEG) The Fan Efficiency Grade FEG is an indicator of the capacity of a Fan to convert Fan shaft power H sh to Fan air power H o The FEG is defined as a function of the Fan Total Peak Efficiency (pte) and Fan size (impeller diameter) Specifications of Minimum FEG shall include a requirement that the Fan Total Efficiency at the actual point of operation be within I0 points of the Fan Total Peak Efficiency.
35 Draft AMCA 205 Fan Efficiency Grade (FEG) Applies to fans driven by motors > I/6 HP (I25 W) Applies to fans consuming more than I000 kwh annually
36 Fan Selection - Practical Considerations Minimum FEG specification Would limit available fan ranges Does not guarantee reduced energy consumption Select within I0 pt pte Assures selections close to pte How restrictive? Next: Survey various fan types Selection examples
37 Fan Selection Achievable Peak Total Efficiency 1 Fan Type pte Centrifugal Airfoil 88 Backward Curved 84 Backward Inclined 80 Forward Curved 70 Vaneaxial 85 Axial Tubeaxial 75 Propeller 55 Mixed Flow 75 Tangential Radgen, et. al. 2008
38 Fan Selection η t P t Flowrate pte P v 10 pts Total Pressure, Total Efficiency
39 Selection Example Range: DWDI AF FEG80 Application: 20 Ton RTU Target Flow: 8000 CFM (13,600 m 3 /h) ISP + ESP: 3 in-wg (750 Pa) P t Size H sh (HP) N (RPM) TE EAE* (kwh) % % % % % EAE = Estimated Annual Energy Usage 90% motor efficiency 90% drive efficiency I00% duty cycle
40 Selection Example FEG 90 FEG 85 FEG 80 Range: DWDI AF FEG85 Application: Size 50 AHU Target Flow: 25,000 CFM (42,500 m 3 /h) ISP + ESP: 6 in-wg (I,500 Pa) P t Fan Peak Total Efficiency % FEG FEG 71 FEG 67 FEG FEG 60 FEG 56 FEG FEG Fan Size (in.) Fan Selections Size η t pte pteη t H sh (HP) Meets the 10 pt limit Drive Power H dc (HP) Specific Fan Power (HP/1000 cfm) Duty Cycle EAE (kwh) 32" Yes " Yes " Yes " No h/day 24 h/day 24 h/day 24 h/day EAE = Estimated Annual Energy Usage 94% motor efficiency 95% drive efficiency
41 Selection Example Range: DWDI AF FEG85 Application: Size 50 AHU Target Flow: 25,000 CFM (42,500 m 3 /h) ISP + ESP: 6 in-wg (I,500 Pa) P t Energy Usage and Cost Estimate Size EAE (kwh) Annual Cost Annual Cost (rel. 32") Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 32" $22,126 28" $23,491 $1,365 $2,730 $4,095 $5,460 $6,825 $8,190 $9,555 25" $25,037 $2,911 $5,822 $8,733 $11,644 $14,555 $17,466 $20,377 22" $28,400 $6,274 $12,548 $18,822 $25,096 $31,370 $37,644 $43,918 EAE = Estimated Annual Energy Usage 94% motor efficiency 95% drive efficiency Electricity cost: $0.11 / kwh
42 Selection Example 60 Range: Direct Drive Plenum FEG80 50 Application: Size 25 AHU 40 Target Flow: 12,000 CFM (20,350 m 3 30 /h) 20 ISP + ESP: 5 in-wg (I,250 Pa) P s Fan Peak Total Efficiency % Fan Size (in.) FEG 90 FEG 85 FEG 80 FEG 75 FEG 71 FEG 67 FEG 63 FEG 60 FEG 56 FEG 53 FEG 50 Size P t η t pt E pte - η t Hi (HP ) Meets I0 pts limit η m Drive Power H dc (HP) Specific Fan Power HP/1000 cfm Duty Cycle EAE (kwh) 25" pt 13.3 Yes HP h/day 93,352 22" pt 15.3 Yes HP h/day 107,396 20" pt 18.8 No HP h/day 131,873 16" x pt 13.6 Yes HP h/day 98,528 EAE = Estimated Annual Energy Usage variable motor efficiency
43 Selection Example Range: DWDI AF FEG75 Baseline: 25,000 6 in-wg (P t ) VAV System Control: 0.75 in-wg Load Profile Fan Range Operation (hours) Total Pressure (in-wg) DWDI AF N = MAX P t p v Flow (kcfm) Flow (kcfm)
44 Selection Example Typical VAV System Curve VAV System Curve Total Pressure, Total Efficiency P t N N max P v VAV Pressure Control Point Flowrate
45 Selection Example Total Pressure (in-wg) Flowrate (kcfm) Energy consumption must include contribution from each operating point on the VAV schedule EAE = H dc1 Δt 1 + H dc2 Δt 2 + H dc2 Δt 2 +
46 Selection Example Effect of baseline pressure 400, Annual Energy Consumption (kwh) 300, , ,000 p t = 8 in-wg p t = 6 in-wg p t = 4 in-wg p t = 2 in-wg Operation (hours) Flow (kcfm) Best TE Acceptable Unacceptable Fan Size (in) Estimated Annual Energy Usage 90% motor efficiency 90% drive efficiency I00% duty cycle
47 Summary Serious efforts to reduce HVAC energy consumption System wide approach: Minimize flow restriction in achieving HVAC goal (greatest impact) Maximize motor/control/drive efficiency Maximize fan efficiency Rating fans for efficiency capability: FEG - fan grade based on shaft/impeller power FMEG - packaged fan/motor/drives Effective only if selection are made close to pte (I0 pts)
48 Questions
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