BUILDING TECHNOLOGIES PROGRAM March 26-27, 2014

ASRAC Pumps Working Group

Scope

2

Scope

• Clearly define scope for this negotiation: Pump Types (VOTE) – VOTED 3/26/14

- Review aggregated results of new surveys if available

- Review updated scenarios for circulator energy use, savings, and payback

• Clearly define scope for negotiation: Scope (VOTE)

- Clean Water/Definition for pumps in scope - Discussed 3/26/14; no vote necessary

- Exclusions – Sanitary pumps - VOTED 3/26/14

- Applicability of standards to pumps with non-electric drivers- VOTED 3/26/14

Metric – To be completed 3/27/14

• Details of possible metric, calculation methods, default values, testing, etc.

• VOTE

Test Procedure

• HI to discuss 40.6 – Discussed 3/26/14

Agenda

3

Applicability of standards to pumps with non-electric drivers

PROPOSAL FOR VOTE: In this rulemaking, the metric will not cover non-electric drivers. The test procedure will specify that the bare pump rating calculations for the energy conservation standard also apply to pumps with non-electric drivers.

• Vote results: Unanimous 3/26/14

Drivers

4

Scope Pump Type DOE Nomenclature

ANSI/HI Nomenclature

Phase 1 - OK End Suction Frame Mounted/Own Bearings ESFM OH0, OH1

Phase 1 - OK End Suction Close Coupled (excludes dedicated pool pumps) ESCC OH7

Phase 1 - OK Inline IL OH3, OH4, OH5

Phase 1 - OK Radial Split (Multistage) Vertical RS-V VS8

Phase 1 - OK Submersible Vertical Turbine (Multistage) VT-S VS0

Phase 2 - OK Circulators N/A CP1, CP2, CP3

Phase 2 - OK Dedicated Swimming Pool Pumps N/A

No – OK Double Suction DS BB1, OH4 double suction

No – OK Multistage Axially Split AS BB1 (2 stage), BB3

No – OK Multistage Radial Split - Horizontal RS-H BB2 (2 stage), BB4

No – OK Multistage Radial Split Vertical Immersible N/A VS1 (immersible)

No – OK Vertical Turbine VT VS1, VS2

No - OK Axial/Mixed Flow OH00, VS3

No - OK Positive Displacement Multiple

No - OK Wastewater, sump, slurry, solids handling pumps Multiple

No - OK API 610 and ASME/ISO chemical process pumps N/A

No - OK Fire Pumps (compliant with NFPA 20 and UL listed or FM approved) N/A

No - OK Self-Priming/Prime Assist Pumps N/A

No - OK Navy and Nuclear Pumps

No - OK Sanitary Pumps

No – OK Pumps outside certain parameters of power, flow head, temperature, speed, and bowl diameter

N/A

Scope for the Negotiation

5

Standard Scope Proposals

• Efficiency Advocates Caucus – Hold circulators (and dedicated-purpose pool pumps) for additional

ASRAC-approved Negotiation • Include schedule in term sheet for this working group

– Target date is term sheet for 2nd negotiation by end of this year (subject DOE capacity) – begin immediately following this negotiation

• Working group recommendation to ASRAC

• HI Proposal – Adopt Lot 11 (ESCC, ESFM, IL, RS-V, VT-S) – Do not adopt any Lot 11+ (DS, AS, RS-H, VT, immersible)

• Savings in Lot 11+ are not great and costs are very high and time consuming • % of DS pumps in market are declining because consumers are switching to

larger end suction pumps that cost less

• EEI Proposal – Move VT from not covered to covered

• PROPOSAL FOR VOTE: Include VT as covered in this rulemaking. – Vote results: 5 Yes 8 No 3 abstain (3/26/14)

• PROPOSAL FOR VOTE: Accepting EE and HI proposals as noted above on the slide. – Vote results: 15 Yes, 1 abstain (consensus 3/26/14)

6

Scope Discussion – Lot 11/HI Proposal

7

Scope Discussion – Lot 11+ (Part 1)

DOE

Nomenclature

ANSI/HI

Nomenclature

Description

Double

Suction

(DS)

BB1 (1 stage) Between bearings, axially split (one-stage)

OH4 (double suction)

Overhung, rigidly coupled, vertical, in-line (double suction)

Axially Split

Multi-Stage

(AS)

BB1 (2 stage) Between bearings, axially split (two-stage)

BB3 Between bearings, axially split (multi-stage)

Radial Split

Horizontal

(RS-H)

BB2 (2 stage) Between bearings, radially split (two-stage)

BB4 Between bearings, radially split, single casing

(multi-stage)

DOE

Nomenclature

ANSI/HI

Nomenclature

Description

Radial Split

Vertical

(RS-V)

N/A Vertically suspended, radial split, immersible

Vertical

Turbine

(VT)

VS1 Vertically suspended, single casing, discharge

through column, diffuser

VS 2 Vertically suspended, single casing, discharge

through column, volute

Axial-Mixed

(A-M)

OH00 Flexibly coupled, horizontal, axial flow

VS3

Vertically suspended, single casing, discharge

through column, axial flow

8

DOE

Nomenclature

ANSI/HI

Nomenclature

Description

Double

Suction

(DS)

BB1 (1 stage) Between bearings, axially split (one-stage)

OH4 (double suction)

Overhung, rigidly coupled, vertical, in-line (double suction)

Axially Split

Multi-Stage

(AS)

BB1 (2 stage) Between bearings, axially split (two-stage)

BB3 Between bearings, axially split (multi-stage)

Radial Split

Horizontal

(RS-H)

BB2 (2 stage) Between bearings, radially split (two-stage)

BB4 Between bearings, radially split, single casing

(multi-stage)

DOE

Nomenclature

ANSI/HI

Nomenclature

Description

Radial Split

Vertical

(RS-V)

N/A Vertically suspended, radial split, immersible

Vertical

Turbine

(VT)

VS1 Vertically suspended, single casing, discharge

through column, diffuser

VS 2 Vertically suspended, single casing, discharge

through column, volute

Axial-Mixed

(A-M)

OH00 Flexibly coupled, horizontal, axial flow

VS3

Vertically suspended, single casing, discharge

through column, axial flow

Scope Discussion – Lot 11+ (Part 2)

RS-V or VT

VS1

9

Scope Discussion – Exclusions Exclusions Notes

OK – 1/31 Wastewater, Sump, Slurry, Solids Handling

Requires further definition? Look at EU documents. (Gray water should not be excluded.)

OK – 1/31 API 610 Pumps

OK – 1/31 ASME/ISO Chemical Pumps

OK – 1/31 Fire Pumps Excluded if compliant with NFPA 20 and UL listed or FM approved.

OK – 1/31 Self-priming pumps

OK – 1/31 Prime-assisted pumps

OK – 1/31 Positive Displacement Pumps

OK – 1/31 Axial/Mixed Flow Pumps

OK – 3/4/14 Nuclear Pumps Complies with ASME Boiler and Pressure Vessel Code Section III or 10CFR50; Non Code or Code/Safety Related. Additional context to be provided.

OK – 3/4/14 Navy Pumps MIL Specification Compliant (MIL-P-17639, MIL-P-17881, MIL-P-17840, MIL-P-18682, MIL-P-18472)

OK – 3/26/14

Sanitary Pumps “Hygienic” or “sanitary” pumps are typically used in food processing and pharmaceutical applications. They are designed with special parameters, specific materials and surface finish to a variety of national and international rules and regulations that will minimize the biological growth inside the pump to protect public health. These design parameters and materials may result in lower efficiencies than for standard water pumps. Certifications for hygienic or sanitary products include, but are not limited to: 3-A Sanitary Standards EHEDG (European Hygienic Equipment Design Group) recommendations QHD (Qualified Hygienic Design)

Definitions to be worked on later (and DOE will review prior to finalization).

PROPOSAL FOR VOTE: This rulemaking will explicitly exclude sanitary pumps, listed as ‘OK – 3/26/2014’

in the table above.

• Vote results: 16 yes (unanimous 3/26/14)

10

Clean Water Definition

• Clean water pump means a pump that is designed for use in pumping clean water, except the following pump types: • A fire pump (as defined) • A self-priming pump (as defined) • A prime-assist pump (as defined) • A pump designed to be used in a nuclear facility subject to

10 CFR 50 (check on ASME) • A pump of designed to comply with a MIL spec • A pump designed for pumping hydrocarbon products that

meets the requirements of API 610/ISO 13709 • A chemical process pump that meets the requirements of

ANSI/ASME B73.1, ANSI/ASME B73.2, or ISO 2858 and ISO 5199

• A sanitary pump that meets the requirements of 3-A sanitary standards

11

Clean Water Definition

Clean water means water with a maximum non-absorbent free solid content of 0.25 kilograms per cubic meter, and with a maximum dissolved solid content of 50 kilograms per cubic meter, provided that the total gas content of the water does not exceed the saturation volume, and disregarding any additives necessary to prevent the water from freezing at a minimum of -10 C

12

Scope Discussion – Updated Shipments (NEMA BIS)

DOE Nomenclature

ANSI/HI

Nomenclature

HI Aggregate

(Units)

Total Industry

Estimate (Units)

HI Proposal

End Suction Close Coupled

(ESCC)

OH7 94,278 171,456

End Suction Frame Mounted

(ESFM/ESOB)

OH0/OH1 31,587 44,042

In-Line (IL) OH3/OH4/OH5 24,406 50,424

Radially Split Vertical (RS-V) VS8 44,527 49,975

Vertical Turbine Submersible

(VT-S)

VS0 78,624 104,406

Additional

Pump Types for

Consideration

Double Suction (DS) BB1/OH4 5,311 5,311

Multi-Stage Axially Split (AS) BB1/BB3 247 277

Multi-Stage Radial Split (RS-H) BB2/BB4 2,874 2,874

Vertical Turbine (VT) VS1/VS2 5,815 5,815

Notes:

In-line shipments (Industry Estimate) is probably too high

All the load factors used are not able to distinguish different fluid types; ESCC and ESFM are too high

Load Factor is supposed to include imports

Lot 11 pumps make up 97% of shipments (units)

13

Scope Discussion – Previous Shipments (for Reference)

Pump Type

# Manufacturers Reporting

Range of Industry Shipments

Estimated by Manufacturers

(0-200 HP) (2012)

Estimated Shipments Based on Manufacturer

Reports and Market Share

(1-200 HP) (2012)

[US Production]

Estimated Shipments Based

on Census (1-200 HP)

(2010) [Shipments+

Imports-Exports] NOTES

Lot 11

ESCC High 24,000 - 460,000 134,000 1,454,000 ESFM High 22,000 - 480,000 92,000 106,800 IL High 8,000 - 90,000 85,000 199,600 RS-V Medium 20,000 - 63,000 88,000 2,280 VT-S Medium 8,000 - 470,000 23,000 3,500

Lot 11+

DS High 900 - 50,000 27,000 6,600 AS Low 400 - 1,600 3,000 150 RS-H Low 2,600 - 71,000 300 2,820 VT Medium 1,300 - 22,000 2,000 12,600

14

Scope Discussion – Updated Energy Use

Pump Type

ANSI/ HI Nomenclat

ure

Estimated Shipments

(NEMA BIS)

Shipment Weighted

Shaft HP at BEP (under

NDA) Connected

Load A (kW) Avg. % Load

Estimated Hours of

Operation (US) A

Estimated Hours of

Operation (EU) B

Annual Energy Use A (TWh)

Annual Energy Use B (TWh)

Energy Savings

Estimate –

MEI/PER 40 Min

Energy Savings

Estimate –

MEI/PER 40 Max

Min Annual Energy Savings (TWh)

Max Annual Energy Savings (TWh)

Lot 11

ESCC OH7 171,456 8 1,061,621 74% 1,913 2,250 1.50 1.77 1.5% 4.3% 0.02 0.08

ESFM OH0/OH1 44,042 19 624,251 74% 2,188 2,250 1.01 1.04 1.0% 2.7% 0.01 0.03

IL OH3/OH4/OH5

50,424 10 376,163 74% 3,000 4,000 0.84 1.11 2.5% 4.1% 0.02 0.05

RS-V VS8 49,975 6 223,688 74% 2,823 1,500 0.47 0.25 1.4% 6.5% 0.003 0.016

VT-S VS0 104,406 16 1,246,190 74% 1,500 1,000 1.38 0.92 2.3% 5.4% 0.02 0.07

Lot 11+

DS BB1/OH4 5,311 80 316,960 74% 3,000 0.70 0.8% 1.8% 0.006 0.01

AS BB1/BB3 277 70 14,465 74% 3,224 0.03 1.6% 3.0% 0.0006 0.0010

RS-H BB2/BB4 2,874 N/A 74% 2,823

VT VS1/VS2 5,815 4 15,183 74% 1,699 0.02 0.1% 0.4% 0.0000 0.0001

Notes: Average percent load is based on an assumed average flow of 50%.

To be updated when full HI data are available – current shaft HP and energy savings

estimates based only on data under NDA. See spreadsheet for updated numbers and notes.

15

Scope Discussion – Previous Energy Use for Reference

Pump Type

ANSI/ HI Nomenclat

ure

Estimated Shipments (1-200 HP)

Wtd Avg HP Manufacturer

Data (1-200 HP)

Median Shaft HP based on HI survey (1-

200 HP)

Connected Load A (kW)

Connected Load B (kW)

Average Percent

Load

Estimated Hours of

Operation (US) A

Estimated Hours of

Operation (EU) B

Annual Energy Use

A (TWh)

Annual Energy Use B (TWh)

Lot 11

ESCC 134,000 10 17 1,020,291 1,699,388 74% 1,913 2,250 1.44 2.83

ESFM 92,000 24 21 1,648,040 1,441,272 74% 2,188 2,250 2.67 2.40

IL 85,000 15 18 933,259 1,141,380 74% 3,000 4,000 2.07 3.38

RS-V 88,000 Not reportable 11 N/A 722,128 74% 2,823 1,500 N/A 0.80

VT-S 23,000 10 4 165,606 68,632 74% 1,500 1,000 0.18 0.05

Lot 11+

DS 27,000 57 1,146,130 74% 3,000 2.54

AS 3,000 56 125,312 74% 3,224 0.30

RS-H 300 Not reportable N/A 74% 2,823 N/A

VT 2,000 78 116,123 74% 1,699 0.15

Notes: Unclear what manufacturer HP data represents (hydraulic, shaft, motor?). May not account for motor efficiency. Average percent load is based on an assumed average flow of 50%.

16

Circulator Notes

• Look at updated data relative to other pumps in Lot 11

• Options – Include in this rulemaking

– Include in Phase 2

– Don’t include

• Operating Hours Assumptions from HI – Heating: 180 days/yr * 12 hrs/day = 2160 hours/yr

– Plumbing Recirculation: 365 days/yr * 6 hours a day = 2190 hours/yr

Literature Range Min Mid Max

Potable Water Recirc 2,190 5,475* 7,300**

Hydronic Heating 2,160 2,520 3,000

Sources: John Siegenthaler presentation, NYSERDA report, TACO white papers, CA IOUs estimate, manufacturer estimates *50% constant; 50% on timer/aquastat operate 6 hours per day **50% constant; 50% on controls operate 16 hours per day

17

Increases in circulator MSP will result from two distinct sources:

1. Increased motor cost

• Switching from Permanent Split Capacitor (PSC) wet-rotor to ECM will increase purchased-parts and/or labor costs

• Motors are either manufactured in-house, or built-to-spec out of house. Circulator motors cannot be bought off-the-shelf.

• There is no publically available data on PSC wet-rotor motor cost, and we have not received enough data to aggregate

- In a rulemaking, we may be able to reverse engineer motor costs

- For this exercise, we extrapolate from off-the-shelf motors in the CRE rulemaking

2. Increased manufacturer markup to cover manufacturer redesign and conversion costs.

Incremental Costs for Circulators

18

CRE rule looked at off-the-shelf PSC and ECM motor costs for shaft powers ranging from 6 to 16 Watts.

A small, 1/25 HP circulator pump requires a shaft wattage of 29.8 Watts.

• Approximately 90 Watts of draw for a PSC and 45 Watts for an ECM.

The CRE cost curves can be extrapolated to 29.8 Watts, with the results:

• PSC: $15.77 • ECM: $30.87 • Ratio of ECM to PSC cost: 2.0

Based on manufacturer provided data, the shipments-weighted-average cost for a 3-Speed, Wet Rotor, PSC Circulator motor is:

• PSC (wet-rotor): $29.50

Assuming the 2.0 cost ratio holds: • ECM (wet-rotor): $59.00

Approximate Incremental Costs of $29.50

Baseline Motors: Cost Extrapolation

$30.87

$15.77

19

Manufacturers were surveyed on estimated redesign and conversion cost, broken out by circulator type and HP range.

Base on survey results, we estimate the following:

Manufacturer Redesign and Conversion Costs

≤1/4 HP

Aggregate Industry Conversion Cost

$39,000,000

Annual Shipments 1,500,000

Estimated Payback Period (Years)

4

Shipments over Payback Period

6,000,000

Incremental Cost per shipment

$6.50

20

Total Incremental Cost: ≤1/4 HP

Motor Cost Conversion

Cost

Incremental Cost $29.50 $6.50

MFG Markup 1.35 Not Applicable

Distribution Markup (Preliminary) 1.55 1.55

Incremental Cost to Customer $61.73 $10.08

TOTAL Incremental Cost to Customer $71.81

21

Updated Circulator Energy Use and Savings Data

Trial 1 Trial 2 Trial 3 Trial 4 Shipments 1,500,000 1,500,000 1,500,000 1,500,000

Average Rated Wattage 104 104 104 104 Percent Variable Speed (ECM) 2.6% 2.6% 2.6% 2.6%

Hours per Year 2,167 3,170 2,167 3,170 TWh 0.33 0.49 0.33 0.49 Percent Savings from ECM (Constant Full Load)

45% 45% 45% 45%

TWh Savings 0.15 0.22 0.15 0.22 Lifetime 10 10 10 10

Quads Savings Over 30 Years 0.38 0.55 0.38 0.55 Electricity Cost ($/kwh) $0.115 $0.115 $0.115 $0.115

Annual Elec Cost Savings $11.66 $17.06 $11.66 $17.06 Incremental Motor Cost $112.50 $112.50 $71.81 $71.81 Payback (years) 9.6 6.6 6.2 4.2

Percent Potable Recirc 22% 22% 22% 22% Percent Hydronic Heating 78% 78% 78% 78%

Operating Hours Potable Recirc 2,190 5,475 2,190 5,475 Operating Hours Hydronic Heating 2,160 2,520 2,160 2,520

See spreadsheet to look at different scenarios

Note: Can use spreadsheet calculator to look at potential savings from running ECM at constant reduced speed.

22

Previous Circulator Energy Use and Savings Data (for Reference) 1/25 - 1/4 HP >1/4 - 3 HP Total

Approximate Shipments

1.5 million 90,000 1.6 million

Operating Hours Annual Constant Full Load Energy Use – 1 Year Shipments (TWh)

2160 0.34 0.12 0.46

3000 0.47 0.17 0.64

6000 0.95 0.33 1.28

Percent Variable Speed Shipments

2.6% 7.4% 2.8%

Potential Annual Savings from ECM at Constant Full Load* - 2160 hours

30 Years of Shipments w/ 7-10 year life (Quads)

Percent Savings 40% 25%

Savings (TWh) 0.13 0.03 0.16 0.29 – 0.41

Cost, Savings, and Payback

Annual Electricity Cost Savings ($)**

$10 $37

Delta Price ($) $113

Payback (years) 12

*Comparing ECM wattage to equivalent AC induction wattage. **11 cents/kWh

23

Agricultural -FRIS Engine Data - Farm & Ranch Irrigation Survey

• Annual Energy Expenses by Type

0

1

2

3

4

5

6

$1-$999 $1000-$1999 $2000-$4999 $5000-$9999 $10000-$19999 $20000-$49999 >$50000

# Fa

rms

x 1

00

00

Total energy expenses for pumping

Electricity

Natural gas

LP gas, propane, and butane

Diesel fuel

• DOE did not receive sales data on pumps sold with engines

24

Other Data: Sales of Pumps with Motors and VFD

Pump Type

% Shipments Packaged with Motor*

% Shipments Packaged with Motor and VFD*

Lot 11

ESCC 65% 3% ESFM 66% 8% IL 92% 9% RS-V Not reportable VT-S Not reportable

Lot 11+

DS 75% 7% AS 95% Not reportable RS-H Not reportable VT 72% 3%

*Shipment weighted average. NOTE: These percentages are for illustration purposes only and are not expected to be representative of the actual market.

• DOE did not receive data on sales of pumps with motors and VFD by HP

To be updated when new data

are available

25

PROPOSAL FOR VOTING: For the purposes of this working group, everything is in scope until this group by their decision-making rules by consensus decides to exclude them.

• Vote results: Unanimous [1/31/14]

Voting Record - Scope Process

26

PROPOSAL FOR VOTING: Although there are now only 16 member in the working group, the ground rules will not change.

• Vote results: Consensus (15 yes with 1 absent) [3/4/2014]

Voting Record - Ground Rules

27

‘Pump’ is a device that moves liquids (which may include entrained gases, free solids, and totally dissolved solids) by physical or mechanical action and includes a bare pump and, if included by the manufacturer and, if included, the mechanical equipment, driver, and controls.

Voting Record - Definition of Covered Product

PROPOSAL FOR VOTING: The covered product, a ‘pump,’ will be defined as in the above paragraph subject to potential edits necessary to accomplish the same intent.

• Vote results: Consensus (15 yes -1 no) [3/4/2014]

28

Voting Record - Description of ‘Pump’ Components

‘Bare pump’ is a ‘pump’ excluding mechanical equipment, driver, and controls.

‘Mechanical equipment’ is any component that transfers energy from the driver to the bare pump.

‘Driver’ is the machine providing mechanical input to drive the bare pump directly or through the mechanical equipment, and may include an electric motor, internal combustion engine, or gas/steam turbine.

‘Controls’ means any device that can be used to control the driver.

PROPOSAL FOR VOTING: The components of a ‘pump’ will be defined as in the above paragraphs.

• Vote results: Consensus (15 yes with 1 absent) [3/4/2014]

29

Voting Record – Scope Exclusions Exclusions Notes

OK – 1/31 Wastewater, Sump, Slurry, Solids Handling

Requires further definition? Look at EU documents. (Gray water should not be excluded.)

OK – 1/31 API 610 Pumps

OK – 1/31 ASME/ISO Chemical Pumps

OK – 1/31 Fire Pumps Excluded if certified to NFPA 20 by UL or FM. Excluded if compliant with NFPA 20 and UL listed or FM approved.

OK – 1/31 Self-priming pumps

OK – 1/31 Prime-assisted pumps

OK – 1/31 Positive Displacement Pumps

OK – 1/31 Axial/Mixed Flow Pumps

OK – 3/4/14 Nuclear Pumps Complies with ASME Boiler and Pressure Vessel Code Section III or 10CFR50; Non Code or Code/Safety Related. Additional context to be provided.

OK – 3/4/14 Navy Pumps MIL Specification Compliant (MIL-P-17639, MIL-P-17881, MIL-P-17840, MIL-P-18682, MIL-P-18472)

TBD Sanitary Pumps Food-grade. Specific physical design requirements that impact efficiency. Significant incremental cost. HI to review prior to next meeting.

Definitions to be worked on later (and DOE will review prior to finalization).

PROPOSAL FOR VOTE: This rulemaking will explicitly exclude the following types of pumps: listed as ‘OK – 1/31’ in the table above. Other

exclusions may be added in the future.

• Vote results: Unanimous [1/31/2014]

PROPOSAL FOR VOTE: This rulemaking will explicitly exclude the following types of pumps: listed as ‘OK – 3/4/2014’ in the table above.

Other exclusions may be added in the future.

• Vote results: Consensus (14 yes with 2 absent) [3/4/2014]

30

HI Standards Parameter Proposal (for only HI recommended pumps):

Voting Record - Parameters

Parameters Notes

OK – 3/4/14 Full impeller diameter OK

OK – 3/4/14 1-200 HP (shaft power at BEP) OK (applies to number of stages required for testing for the standard)

OK – 3/4/14 25 gpm and greater (at BEP) OK

OK – 3/4/14 459 feet of head maximum (at BEP) OK

OK – 3/4/14 Design temperature range from -10 to 120 degrees C

OK

OK – 3/4/14 Pumps designed for nominal 3600 or 1800 rpm driver speeds

OK – 3/4/14 6” or smaller bowl diameter (VT-S/HI VS0)

PROPOSAL FOR VOTE: For pumps recommended by HI, this rulemaking will be limited to pumps with the characteristics listed in the table above as ‘OK – 3/4/14.’ Modifications or additional parameters may be determined for additional pump types not recommended by HI. • Vote results: Consensus (15 yes with 1 absent) [3/4/14]