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Motor replacement and VFD savings

Enter the motor, its efficiency class, the control method and the flow profile to compare a motor replacement, a drive or both, with energy use, savings and payback.

Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.

Pre-sizing
Motor and load
Motor replacement
Flow control

Static head ÷ total head at full flow. Fans and closed loops are near 0%; lifting water to a tank can exceed 60%.

Flow profile over the year

Investment
Economic analysis
—Annual energy savings
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Electric power at each flow

Comparison of the current setup, new motor only, drive only and both together.

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Annual energy cost by scenario

How much each option spends per year and how much it saves versus the current setup.

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Motor efficiency vs load

Estimated curves for the current and new motor; points show where each operates.

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Project payback

Cash flow of the improvement: investment in year 0 and annual savings escalated at the rate entered, discounted at the MARR.

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The report gathers this page's inputs, results, equations, assumptions and references, with fields for project, engineer and revision. In the print dialog, choose Save as PDF.

Method, assumptions and references

Equations used

Shaft power at full flow: P0 = Prated · load factor
Efficiency vs load: η(λ) = λ ÷ (λ + Lfl · (0.35 + 0.65 · λ²)), with Lfl = 1/ηrated − 1
Throttling (pump): P/P0 = (1.25 − 0.25 · q²) ÷ (2 − q); outlet damper (fan): P/P0 = 0.5 + 0.5 · q
Drive: P/P0 = q · (hs + (1 − hs) · q²), divided by drive efficiency (97%)
Annual energy: E = Σ Pel,i · ti · hours; savings = (Ecurrent − Eproposed) · rate

Assumptions and limits

  • Nominal efficiencies from NEMA MG 1 (60 Hz, 4-pole, TEFC). IE1 estimated with 25% more losses than IE2 and IE4 with 20% fewer losses than IE3.
  • Loss split of 35% fixed and 65% load-dependent, typical of 4-pole induction motors.
  • Throttling and damper curves are typical averages (DOE / Hydraulic Institute); the real curve depends on the pump or fan. The drive is modeled at a constant 97% efficiency.
  • Excludes demand charge savings, power factor, harmonics and maintenance.

Standards and technical documents

  • IEC 60034-30-1:2014: Efficiency classes of line operated AC motors (IE code)
  • NEMA MG 1-2021, Tables 12-11 and 12-12: nominal full-load efficiencies
  • ABNT NBR 17094-1: Máquinas elétricas girantes — Motores de indução trifásicos
  • IEC 61800-9-2:2017: Energy efficiency indicators for power drive systems (IES classes)
  • US DOE, Motor Systems Tip Sheets #3 and #11; Hydraulic Institute / Europump, Variable Speed Pumping: A Guide to Successful Applications

U.S. regulations

  • 10 CFR 431 Subpart B: DOE energy conservation standards for electric motors (NEMA Premium levels since 2016)
  • Energy Independence and Security Act of 2007 (EISA), Section 313
  • NFPA 70 (NEC) Article 430: motors, motor circuits and controllers; NFPA 70E for electrical safety in the workplace

Frequently asked questions

Is it worth replacing a motor that still runs?

It depends on running hours and efficiency gap. Motors with long annual hours, old or rewound several times often pay back in 2 to 4 years. With few hours, replacing on failure usually makes more sense.

How much does a VFD save?

On pumps and fans with variable flow and little static head, power falls roughly with the cube of flow. Running at 80% flow needs about half the power. With this page’s default profile, savings exceed 30%.

Can standard efficiency motors still be sold in the US?

No. Under 10 CFR 431, most general-purpose motors from 1 to 500 hp sold in the US must meet NEMA Premium (IE3) efficiency since June 2016.