10 C.F.R. § 431 app A to Subpart Y of Part 431
Note: Prior to September 20, 2023, representations with respect to the energy use or efficiency (including compliance certifications) of pumps specified in § 431.464(a)(1)(i) , excluding pumps listed in § 431.464(a)(1)(iv) , must be based on testing conducted in accordance with the applicable provisions of this appendix as they appeared in the January 1, 2022 edition of the Code of Federal Regulations of subpart Y of part 431 in 10 CFR parts 200 through 499 .
On or after September 20, 2023, representations with respect to the energy use or efficiency (including compliance certifications) of pumps specified in § 431.464(a)(1)(i) , excluding pumps listed in § 431.464(a)(1)(iv) , must be based on testing conducted in accordance with the applicable provisions of this appendix.
Any representations with respect to the energy use or efficiency of pumps specified in § 431.464(a)(1)(ii) , excluding pumps listed in § 431.464(a)(1)(iv) , made on or after September 20, 2023 must be made in accordance with the results of testing pursuant to this appendix. Manufacturers must use the results of testing under this appendix to determine compliance with any energy conservation standards established for pumps specified in § 431.464(a)(1)(ii) , excluding pumps listed in § 431.464(a)(1)(iv) , that are published after January 1, 2022.
I. Test Procedure for Pumps
0. Incorporation by Reference.
DOE incorporated by reference in § 431.463 the entire standard for HI 40.6-2021, HI 9.6.1-2017, HI 9.6.6-2016, HI 9.8-2018, HI 14.1-14.2-2019, the HI Engineering Data Book, ASME MFC-5M-1985, ASME MFC-3M-2004, ASME MFC-8M-2001, ASME MFC-12M-2006, ASME MFC-16-2014, ASME MFC-22-2007, AWWA E103-2015, CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, ISO 1438:2017, ISO 2186:2007, ISO 2715:2017, ISO 3354:2008, ISO 3966:2020, ISO 5167-1:2003, ISO 5198:1987, ISO 6416:2017, and ISO 20456:2017; however, certain enumerated provisions of HI 40.6-2021, as follows are inapplicable. To the extent that there is a conflict between the terms or provisions of a referenced industry standard and the CFR, the CFR provisions control.
0.1 HI 40.6-2021
(a) Section 40.6.1 Scope
(b) Section 40.6.5.3 Test report
(c) Appendix B Reporting of test results (informative)
(d) Appendix E Testing Circulator Pumps (normative)
(e) Appendix G DOE Compared to HI 40.6 Nomenclature
0.2 [Reserved]
A. General. To determine the constant load pump energy index (PEICL) for bare pumps and pumps sold with electric motors or the variable load pump energy index (PEIVL) for pumps sold with electric motors and continuous or non-continuous controls, perform testing in accordance with HI 40.6-2021, except section 40.6.5.3 , "Test report", including the applicable provisions of HI 9.6.1-2017, HI 9.6.6-2016, HI 9.8-2018, HI 14.1-14.2-2019, the HI Engineering Data Book, ASME MFC-3M-2004, ASME MFC-5M-1985, ASME MFC-8M-2001, ASME MFC-12M-2006, ASME MFC-16-2014, ASME MFC-22-2007, AWWA E103-2015, CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, ISO 1438:2017, ISO 2186:2007, ISO 2715:2017, ISO 3354:2008, ISO 3966:2020, ISO 5167-1:2003, ISO 5198:1987, ISO 6416:2017, and ISO 20456:2017, as referenced in HI 40.6, with the modifications and additions as noted throughout the provisions below. Where HI 40.6-2021 refers to "pump," the term refers to the "bare pump," as defined in § 431.462 . Also, for the purposes of applying this appendix, the term "volume per unit time," as defined in section 40.6.2 , "Terms and definitions," of HI 40.6-2021 shall be deemed to be synonymous with the term "flow rate" used throughout that standard and this appendix. In addition, the specifications in section 40.6.4.1 of HI 40.6-2021, "Vertically suspended pumps," do not apply to ST pumps and the performance of ST bare pumps considers bowl performance only. However, the specifications in the first paragraph of section 40.6.4.1 of HI 40.6-2021 (including the applicable provisions of HI 14.1-14.2-2019, the HI Engineering Data Book, and AWWA E103-2015, as referenced in section 40.6.4.1 of HI 40.6), "Vertically suspended pumps," do apply to VT pumps and the performance of VT bare pumps considers bowl performance only.
A. 1 Scope. Section II of this appendix applies to all pumps and describes how to calculate the pump energy index (section II.A) based on the pump energy rating for the minimally-compliant reference pump (PERSTD; section II.B) and the constant load pump energy rating (PERCL) or variable load pump energy rating (PERVL) determined in accordance with one of sections III through VII of this appendix, based on the configuration in which the pump is distributed in commerce and the applicable testing method specified in sections III through VII and as described in Table 1 of this appendix.
Table 1-Applicability of Calculation-Based and Testing-Based Test Procedure Options Based on Pump Configuration
| Pump configuration | Pump sub-configuration | Applicable test methods |
| Bare Pump | Bare Pump OR Pump + Single-Phase Induction Motor (Excluding SVIL) OR Pump + Driver Other Than Electric Motor | Section III: Test Procedure for Bare Pumps. |
| Pump + Motor OR Pump + Motor + Controls other than continuous or non-continuous controls (e.g., ON/OFF switches) | Pump + Motor Listed at § 431.25(g) OR SVIL Pump + Motor Covered by DOE's Test Procedure and/or Energy Conservation Standards * OR Pump + Submersible Motor | Section IV: Testing-Based Approach for Pumps Sold with Motors OR Section V: Calculation-Based Approach for Pumps Sold with Motors. |
| Pump (Including SVIL) + Motor Not Covered by DOE's Motor Energy Conservation Standards (Except Submersible Motors) ** OR Pump (Other than SVIL) + Single-Phase Induction Motor (if Section III is not used) | Section IV: Testing-Based Approach for Pumps Sold with Motors. | |
| Pump + Motor + Continuous Controls OR Pump + Motor + Non-Continuous Controls OR Pump + Inverter-Only Synchronous Electric Motor *** (With or Without Controls) | Pump + Motor Listed at § 431.25(g) + Continuous Control OR SVIL Pump + Motor Covered by DOE's Test Procedure and/or Energy Conservation Standards * + Continuous Control OR Pump + Submersible Motor + Continuous Control OR Pump + Inverter-Only Synchronous Electric Motor *** (With or Without Continuous Control) | Section VI: Testing-Based Approach for Pumps Sold with Motors and Controls OR Section VII: Calculation-Based Approach for Pumps Sold with Motors Controls. |
| Pump + Motor Listed at § 431.25(g) + Non-Continuous Control OR SVIL Pump + Motor Covered by DOE's Test Procedure and/or Energy Conservation Standards * + Non-Continuous Control OR Pump + Submersible Motor + Non-Continuous Control | Section VI: Testing-Based Approach for Pumps Sold with Motors and Controls. | |
| Pump (Including SVIL) + Motor Not Covered by DOE's Motor Test Procedure and/or Energy Conservation Standards ** (Except Submersible Motors) + Continuous or Non-Continuous Controls OR Pump (Other than SVIL) + Single-Phase Induction Motor + Continuous or Non-Continuous Controls (if Section III is not used) | Section VI: Testing-Based Approach for Pumps Sold with Motors and Controls. |
* All references to "Motor Covered by DOE's Motor Test Procedure and/or Energy Conservation Standards" refer to those listed at § 431.446 of this chapter or those for Small Non-Small Electric Motor Electric Motors (SNEMs) at Subpart B to Part 431, including motors of such varieties that are less than 0.25 hp.
** All references to "Motor Not Covered by DOE's Test Procedure and/or Motor Energy Conservation Standards" refer to motors not listed at § 431.25 of this chapter or, for SVIL, not listed at either § 431.446 of this chapter or in Subpart B to Part 431 (excluding motors of such varieties that are less than 0.25 hp).
*** All references to "Inverter-Only Synchronous Electric Motor" refer to inverter-only electric motors that are synchronous electric motors, both as defined in subpart B to Part 431.
A. 2 Section III of this appendix addresses the test procedure applicable to bare pumps. This test procedure also applies to pumps sold with drivers other than motors and ESCC, ESFM, IL, RSHES, RSHIL, RSV, ST, and VT pumps sold with single-phase induction motors.
A. 3 Section IV of this appendix addresses the testing-based approach for pumps sold with motors, which applies to all pumps sold with electric motors, except for pumps sold with inverter-only synchronous electric motors, but including pumps sold with single-phase induction motors. This test procedure also applies to pumps sold with controls other than continuous or non-continuous controls (e.g., on/off switches).
A. 4 Section V of this appendix addresses the calculation-based approach for pumps sold with motors, which applies to:
A. 4.1 Pumps sold with polyphase electric motors regulated by DOE's energy conservation standards for electric motors at § 431.25(g) , and
A. 4.2 SVIL pumps sold with small electric motors regulated by DOE's energy conservation standards at § 431.446 or sold with SNEMs regulated by DOE's test procedure and/or energy conservation standards in subpart B of this part but including motors of such varieties that are less than 0.25 hp, and
A. 4.3 Pumps sold with submersible motors.
A. 5 Section VI of this appendix addresses the testing-based approach for pumps sold with motors and controls, which applies to all pumps sold with electric motors (including single-phase induction motors) and continuous or non-continuous controls and to pumps sold with inverter-only synchronous electric motors with or without controls.
A. 6 Section VII of this appendix discusses the calculation-based approach for pumps sold with motors and controls, which applies to:
A. 6.1 Pumps sold with polyphase electric motors regulated by DOE's energy conservation standards for electric motors at § 431.25(g) and continuous controls and
A. 6.2 Pumps sold with inverter-only synchronous electric motors regulated by DOE's test procedure and/or energy conservation standards in subpart B of this part,
A. 6.3 SVIL pumps sold with small electric motors regulated by DOE's energy conservation standards at § 431.446 (but including motors of such varieties that are less than 0.25 hp) and continuous controls or with SNEMs regulated by DOE's test procedure and/or energy conservation standards at subpart B of this part (but including motors of such varieties that are less than 0.25 hp) and continuous controls, and
A. 6.4 Pumps sold with submersible motors and continuous controls.
B. Measurement Equipment.
B.1 Instrument Accuracy. For the purposes of measuring pump power input, driver power input to the motor or controls, and pump power output, the equipment specified in HI 40.6-2021 Appendix C (including the applicable provisions of ASME MFC-5M-1985, ASME MFC-3M-2004, ASME MFC-8M-2001, ASME MFC-12M-2006, ASME MFC-16-2014, ASME MFC-22-2007, CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, ISO 1438:2017, ISO 2186:2007, ISO 2715:2017, ISO 3354:2008, ISO 3966:2020, ISO 5167-1:2003, ISO 5198:1987, ISO 6416:2017, and ISO 20456:2017, as referenced in Appendix C of HI 40.6) necessary to measure head, speed of rotation, flow rate, temperature, torque, and electrical power must be used and must comply with the stated accuracy requirements in HI 40.6-2021 Table 40.6.3.2.3 except as noted in sections III.B, IV.B, V.B, VI.B, and VII.B of this appendix. When more than one instrument is used to measure a given parameter, the combined accuracy, calculated as the root sum of squares of individual instrument accuracies, must meet the specified accuracy requirements.
B. 2 Calibration. Calibration requirements for instrumentation are specified in Appendix D of HI 40.6-2021.
C. Test Conditions. Conduct testing at full impeller diameter in accordance with the test conditions, stabilization requirements, and specifications of HI 40.6-2021 Section 40.6.3 , "Pump efficiency testing;" Section 40.6.4 , "Considerations when determining the efficiency of certain pumps" including the applicable provisions of HI 14.1-14.2-2019, the HI Engineering Data Book, and AWWA E103-2015, as referenced in section 40.6.4 of HI 40.6; section 40.6.5.4 (including appendix A), "Test arrangements," including the applicable provisions of HI 9.6.1-2017, HI 9.6.6-2016, HI 9.8-2018, HI Engineering Data Book, and AWWA E103-2015 as referenced in appendix A of HI 40.6; and section 40.6.5.5 , "Test conditions" including the applicable provisions of HI 9.6.1-2017 as referenced in section 40.6.5.5.1 of HI 40.6-2021. For ST pumps, head measurements must be based on the bowl assembly total head as described in section A.5 of 40.6-2021, including the applicable provisions of the HI Engineering Data Book and AWWA E103-2015 as referenced in ins section A.5 of HI 40.6-2021, and the pump power input or driver power input, as applicable, must be based on the measured input power to the driver or bare pump, respectively; section 40.6.4.1 , "Vertically suspended pumps," does not apply to ST pumps.
C. 1 Nominal Speed of Rotation. Determine the nominal speed of rotation based on the range of speeds of rotation at which the pump is designed to operate, in accordance with sections I.C.1.1, I.C.1.2, and I.C.1.3 of this appendix, as applicable. When determining the range of speeds at which the pump is designed to operate, DOE will refer to published data, marketing literature, and other publicly-available information about the pump model and motor, as applicable.
C. 1.1 For pumps sold without motors, select the nominal speed of rotation based on the speed for which the pump is designed.
C. 1.1.1 For bare pumps designed for speeds of rotation including 2,880 to 4,320 revolutions per minute (rpm), the nominal speed of rotation shall be 3,600 rpm.
C. 1.1.2 For bare pumps designed for speeds of rotation including 1,440 to 2,160 rpm, the nominal speed of rotation shall be 1,800 rpm.
C. 1.1.3 For bare pumps designed for speeds of rotation including 960 to 1,439 rpm, the nominal speed of rotation shall be 1,200 rpm.
C. 1.2 For pumps sold with induction motors, select the appropriate nominal speed of rotation.
C. 1.2.1 For pumps sold with 6-pole induction motors, the nominal speed of rotation shall be 1,200 rpm.
C. 1.2.2 For pumps sold with 4-pole induction motors, the nominal speed of rotation shall be 1,800 rpm.
C. 1.2.3 For pumps sold with 2-pole induction motors, the nominal speed of rotation shall be 3,600 rpm.
C. 1.3 For pumps sold with non-induction motors, select the appropriate nominal speed of rotation.
C. 1.3.1 Where the operating range of the pump and motor includes speeds of rotation between 2,880 and 4,320 rpm, the nominal speed of rotation shall be 3,600 rpm.
C. 1.3.2 Where the operating range of the pump and motor includes speeds of rotation between 1,440 and 2,160 rpm, the nominal speed of rotation shall be 1,800 rpm.
C. 1.3.3 Where the operating range of the pump and motor includes speeds of rotation between 960 and 1,439, the nominal speed of rotation shall be 1,200 rpm.
C. 2 Multi-Stage Pumps. Perform testing on the pump with three stages for RSH and RSV pumps, and nine stages for ST and VT pumps. If the basic model of pump being tested is only available with fewer than the required number of stages, test the pump with the maximum number of stages with which the basic model is distributed in commerce in the United States. If the basic model of pump being tested is only available with greater than the required number of stages, test the pump with the lowest number of stages with which the basic model is distributed in commerce in the United States. If the basic model of pump being tested is available with both fewer and greater than the required number of stages, but not the required number of stages, test the pump with the number of stages closest to the required number of stages. If both the next lower and next higher number of stages are equivalently close to the required number of stages, test the pump with the next higher number of stages.
C. 3 Twin-Head Pumps. For twin-head pumps, perform testing on an equivalent single impeller IL or SVIL pump as applicable, constructed by incorporating one of the driver and impeller assemblies of the twin-head pump being rated into an adequate IL-style or SVIL-style, single impeller volute and casing. An adequate IL-style or SVIL-style, single impeller volute and casing means a volute and casing for which any physical and functional characteristics that affect energy consumption and energy efficiency are the same as their corresponding characteristics for a single impeller in the twin-head pump volute and casing.
D. Data Collection and Analysis.
D. 1 Damping Devices. Use of damping devices, as described in section 40.6.3.2.2 of HI 40.6-2021, are only permitted to integrate up to the data collection interval used during testing.
D. 2 Stabilization. Record data at any tested load point only under stabilized conditions, as defined in HI 40.6-2021 section 40.6.5.5.1 , including the applicable provisions of HI 9.6.1-2017 as referenced in section 40.6.5.5.1 of HI 40.6, where a minimum of two measurements are used to determine stabilization.
D. 3 Calculations and Rounding. Normalize all measured data to the nominal speed of rotation of 3,600 or 1,800 or 1,200 rpm based on the nominal speed of rotation selected for the pump in section I.C.1 of this appendix, in accordance with the procedures specified in section 40.6.6.1.1 of HI 40.6-2021. Except for the "expected BEP flow rate," all terms and quantities refer to values determined in accordance with the procedures set forth in this appendix for the rated pump. Perform all calculations using raw measured values without rounding. Round PERCL and PERVL to three significant digits, and round PEICL, and PEIVL values, as applicable, to the hundredths place (i.e., 0.01).
D. 4 Pumps with BEP at Run Out. Test pumps for which the expected BEP corresponds to a volume rate of flow that is within 20 percent of the expected maximum flow rate at which the pump is designed to operate continuously or safely (i.e., pumps with BEP at run-out) in accordance with the test procedure specified in this appendix, but with the following exceptions:
D. 4.1 Use the following seven flow points-40, 50, 60, 70, 80, 90, and 100 percent of the expected maximum flow rate for determination of BEP in sections III.D, IV.D, V.D, VI.D, and VII.D of this appendix instead of the flow points specified in those sections.
D. 4.2 Use flow points of 60, 70, 80, 90, and 100 percent of the expected maximum flow rate of the pump to determine pump power input or driver power input instead of the flow points of 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate specified in sections III.E.1.1, IV.E.1, V.E.1.1, VI.E.1, and VII.E.1.1 of this appendix.
D. 4.3 To determine PERCL in sections III.E, IV.E, and V.E and to determine PERSTD in section II.B, use load points of 65, 90, and 100 percent of the BEP flow rate determined with the modified flow points specified in this section I.D.4 of this appendix instead of 75, 100, and 110 percent of BEP flow. In section II.B.1.1, where alpha values are specified for the load points 75, 100, and 110 percent of BEP flow rate, instead apply the alpha values to the load points of 65, 90, and 100 percent of the BEP flow rate determined with the modified flow points specified in this section I.D.4 of this appendix. However, in sections II.B.1.1.1 and II.B.1.1.1.1 of this appendix, use 100 percent of the BEP flow rate as specified to determine [ETA]pump,STD and Ns as specified. To determine motor sizing for bare pumps in sections II.B.1.2.1.1 and III.E.1.2.1.1 of this appendix, use a load point of 100 percent of the BEP flow rate instead of 120 percent.
II. Calculation of the Pump Energy Index
A. Determine the PEI of each tested pump based on the configuration in which it is sold, as follows:
A.
1. For pumps rated as bare pumps or pumps sold with motors (other than inverter-only synchronous electric motors), determine the PEICL using the following equation:
Where:
PEICL = the pump energy index for a constant load (hp),
PERCL = the pump energy rating for a constant load (hp), determined in accordance with either section III (for bare pumps; ESCC, ESFM, IL, RSHES, RSHIL, RSV, ST or VT pumps sold with single-phase induction motors; and pumps sold with drivers other than electric motors), section IV (for pumps sold with motors and rated using the testing-based approach), or section V (for pumps sold with motors and rated using the calculation-based approach) of this appendix, and
PERSTD = the PERCL for a pump that is minimally compliant with DOE's energy conservation standards with the same flow and specific speed characteristics as the tested pump (hp), as determined in accordance with section II.B of this appendix.
A. 2 For pumps rated as pumps sold with motors and continuous controls or non-continuous controls (including pumps sold with inverter-only synchronous electric motors with or without controls), determine the PEIVL using the following equation:
PEIVL = the pump energy index for a variable load (hp),
PERVL = the pump energy rating for a variable load (hp), determined in accordance with section VI (for pumps sold with motors and continuous or non-continuous controls rated using the testing-based approach) or section VII of this appendix (for pumps sold with motors and continuous controls rated using the calculation-based approach), and
PERSTD = the PERCL for a pump that is minimally compliant with DOE's energy conservation standards with the same flow and specific speed characteristics as the tested pump (hp), as determined in accordance with section II.B of this appendix.
B. Determine the pump energy rating for the minimally compliant reference pump (PERSTD), according to the following equation:
Where:
PERSTD = the PERCL for a pump that is minimally compliant with DOE's energy conservation standards with the same flow and specific speed characteristics as the tested pump (hp),
[OMEGA]i = 0.3333,
Piin,m = calculated driver power input to the motor at load point i for the minimally compliant pump (hp), calculated in accordance with section II.B.1of this appendix, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
B.
1. Determine the driver power input at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Where:
Piin,m = driver power input to the motor at load point i (hp),
Pi = pump power input to the bare pump at load point i (hp), calculated in accordance with section II.B.1.1 of this appendix,
Li = the part load motor losses at load point i (hp), calculated in accordance with section II.B.1.2 of this appendix, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
B.1.1. Determine the pump power input to the minimally compliant pump at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Where:
Pi = pump power input to the bare pump at load point i (hp),
[ALPHA]i = 0.947 for 75 percent of the BEP flow rate, 1.000 for 100 percent of the BEP flow rate, and 0.985 for 110 percent of the BEP flow rate;
Pu,i = the pump power output at load point i of the tested pump (hp), as determined in accordance with section II.B.1.1.2 of this appendix;
[ETA]pump,STD = the minimally compliant pump efficiency (%), calculated in accordance with section II.B.1.1.1 of this appendix; and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
B.1.1.1 Calculate the minimally compliant pump efficiency based on the following equation:
[ETA]pump,STD = -0.8500 * ln(Q100`)2 -0.3800 * ln(Ns) * ln(Q100`) - 11.480 * ln(Ns)2 + 17.800 * ln(Q100`) + 179.80 * ln(Ns) - (C + 555.60
Where:
[ETA]pump,STD = minimally compliant pump efficiency (%),
Q100` = the BEP flow rate of the tested pump at full impeller and nominal speed of rotation (gpm),
Ns = specific speed of the tested pump determined in accordance with section II.B.1.1.1.1 of this appendix, and
C = the appropriate C-value for the category and nominal speed of rotation of the tested pump, as listed at § 431.466 .
B.1.1.1.1 Determine the specific speed of the rated pump using the following equation:
Where:
Ns = specific speed,
nsp = the nominal speed of rotation (rpm),
Q'100% = the measured BEP flow rate of the tested pump at full impeller and nominal speed of rotation (gpm),
H100% = pump total head at 100 percent of the BEP flow rate of the tested pump at full impeller and nominal speed of rotation (ft), and
S = the number of stages with which the pump is being rated
B.1.1.2 Determine the pump power output at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate using the following equation:
Where:
Pu,i = the measured pump power output at load point i of the tested pump (hp),
Qi = the measured flow rate at load point i of the tested pump (gpm),
Hi = pump total head at load point i of the tested pump (ft),
SG = the specific gravity of water at specified test conditions, which is equivalent to 1.00, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
B.1.2 Determine the motor part load losses at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Li = Lfull * yi
Where:
Li = part load motor losses at load point i (hp),
Lfull = motor losses at full load (hp), as determined in accordance with section II.B.1.2.1 of this appendix,
yi = part load loss factor at load point i determined in accordance with section II.B.1.2.2 of this appendix, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
B.1.2.1 Determine the full load motor losses using the appropriate motor efficiency value and horsepower as shown in the following equation:
Where:
Lfull = motor losses at full load (hp),
MotorHP = the motor horsepower as determined in accordance with section II.B.1.2.1.1 of this appendix (hp), and
[ETA]motor,full = the default nominal full load motor efficiency as determined in accordance with section II.B.1.2.1.2 of this appendix (%).
B.1.2.1.1 Determine the motor horsepower as follows:
For bare pumps other than ST pumps, the motor horsepower is determined as the horsepower rating listed in Table 2 of this appendix that is either equivalent to, or the next highest horsepower greater than, the pump power input to the bare pump at 120 percent of the BEP flow rate of the tested pump. For ST bare pumps, the motor horsepower is determined as the horsepower rating listed in Table 2 of this appendix that, is either equivalent to, or the next highest horsepower greater than, the pump power input to the bare pump at 120 percent of the BEP flow rate of the tested pump divided by a service factor of 1.15. For pumps sold with motors, pumps sold with motors and continuous controls, or pumps sold with motors and non-continuous controls, the motor horsepower is the rated horsepower of the motor with which the pump is being tested.B. 1.2.1.2 Determine the default nominal full load motor efficiency as described in section II.B.1.2.1.2.1 of this appendix for ESCC, ESFM, IL, RSHES, RSHIL, RSV, and VT pumps; section II.B.1.2.1.2.2 of this appendix for ST pumps; and section II.B.1.2.1.2.3 for SVIL pumps.
B. 1.2.1.2.1. For ESCC, ESFM, IL, RSHES, RSHIL, RSV, and VT pumps, the default nominal full load motor efficiency is the minimum of the nominal full load motor efficiency standards (open or enclosed) from the table containing the current energy conservation standards for NEMA Design B motors at § 431.25 , with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower determined in section II.B.1.2.1.1 of this appendix.
B. 1.2.1.2.2. For ST pumps, prior to the compliance date of any energy conservation standards for submersible motors in subpart B of this part, the default nominal full load motor efficiency is the default nominal full load submersible motor efficiency listed in table 2 of this appendix, with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower determined in section II.B.1.2.1.1 of this appendix. Starting on the compliance date of any energy conservation standards for submersible motors in subpart B of this part, the default nominal full load motor efficiency shall be the minimum of any nominal full load motor efficiency standard from the table containing energy conservation standards for submersible motors in subpart B of this part, with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower determined in section II.B.1.2.1.1 of this appendix.
B. 1.2.1.2.3. For SVIL pumps, the default nominal full load motor efficiency is the minimum full load motor efficiency standard from the tables containing the current energy conservation standards for polyphase or CSCR/CSIR small electric motors at § 431.446 , with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower determined in section II.B.1.2.1.1 of this appendix, or for SVIL pumps sold with motors less than 0.25 hp, the default nominal full load motor efficiency is 58.3% for 6-pole, 64.6% for 4-pole, and 61.7% for 2-pole motors.
B. 1.2.2 Determine the part load loss factor at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Where:
yi = the part load loss factor at load point i,
Pi = pump power input to the bare pump at load point i (hp),
MotorHP = the motor horsepower (hp), as determined in accordance with section II.B.1.2.1.1 of this appendix,
III. Test Procedure for Bare Pumps
A. Scope. This section III applies only to:
A. 1 Bare pumps,
A. 2 Pumps sold with drivers other than electric motors, and
A. 3 ESCC, ESFM, IL, RSHES, RSHIL, RSV, ST, and VT pumps sold with single-phase induction motors.
B.Measurement Equipment. The requirements regarding measurement equipment presented in section I.B of this appendix apply to this section III. In addition, when testing pumps using a calibrated motor, electrical measurement equipment shall meet the requirements of section C.4.3 of HI 40.6-2021 (including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3 of HI 40.6), and motor power input shall be determined according to section 40.6.3.2.3 of HI 40.6-2021 and meet the requirements in Table 40.6.3.2.3 of HI 40.6-2021.
C.Test Conditions. The requirements regarding test conditions presented in section I.C of this appendix apply to this section III. In addition, when testing pumps using a calibrated motor, the conditions in section C.4.3.1 of HI 40.6-2021 shall be met, including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3.1 of HI 40.6-2021.
D.Testing BEP for the Pump. Determine the best efficiency point (BEP) of the pump as follows:
D.
1. Adjust the flow by throttling the pump without changing the speed of rotation of the pump and conduct the test at a minimum of the following seven flow points: 40, 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate of the pump at the nominal speed of rotation, as specified in section 40.6.5.5.1 of HI 40.6-2021, including the applicable provisions of HI 9.6.1-2017 as referenced in section 40.6.5.5.1 of HI 40.6-2021.
D.
2. Determine the BEP flow rate as the flow rate at the operating point of maximum pump efficiency on the pump efficiency curve, as determined in accordance with section 40.6.6.3 of HI 40.6-2021, where the pump efficiency is the ratio of the pump power output divided by the pump power input, as specified in Table 40.6.2 of HI 40.6-2021, disregarding the calculations provided in section 40.6.6.2 of HI 40.6-2021.
E. Calculating the Constant Load Pump Energy Rating. Determine the PERCL of each tested pump using the following equation:
Where:
PERCL = the pump energy rating for a constant load (hp),
[OMEGA]i = 0.3333,
Piin,m = calculated driver power input to the motor at load point i (hp), as determined in accordance with section III.E.1 of this appendix, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
E. 1 Determine the driver power input at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Where:
Piin,m = driver power input to the motor at load point i (hp),
Pi = pump power input to the bare pump at load point i (hp), as determined in section III.E.1.1 of this appendix,
Li = the part load motor losses at load point i (hp), as determined in accordance with section III.E.1.2 of this appendix, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
E. 1.1 Determine the pump power input at 75, 100, 110, and 120 percent of the BEP flow rate by employing a least squares regression to determine a linear relationship between the pump power input at the nominal speed of rotation of the pump and the measured flow rate at the following load points: 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate. Use the linear relationship to determine the pump power input at the nominal speed of rotation for the load points of 75, 100, 110, and 120 percent of the BEP flow rate.
E. 1.2 Determine the motor part load losses at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Li = Lfull * yi
Where:
Li = motor losses at load point i (hp),
Lfull = motor losses at full load (hp), as determined in accordance with section III.E.1.2.1 of this appendix,
yi = loss factor at load point i as determined in accordance with section III.E.1.2.2 of this appendix, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
E. 1.2.1 Determine the full load motor losses using the appropriate motor efficiency value and horsepower as shown in the following equation:
Where:
Lfull = motor losses at full load (hp);
MotorHP = the motor horsepower (hp), as determined in accordance with section II.E.1.2.1.1 of this appendix, and
[ETA]motor,full = the default nominal full load motor efficiency (%), as determined in accordance with section III.E.1.2.1.2 of this appendix.
E. 1.2.1.1 Determine the motor horsepower as follows:
For bare pumps other than ST pumps, determine the motor horsepower by selecting the horsepower rating listed in Table 2 of this appendix that is either equivalent to, or the next highest horsepower greater than, the pump power input to the bare pump at 120 percent of the BEP flow rate of the tested pump. For ST bare pumps, determine the motor horsepower by selecting the horsepower rating listed in Table 2 of this appendix that, is either equivalent to, or the next highest horsepower greater than, the pump power input to the bare pump at 120 percent of the BEP flow rate of the tested pump divided by a service factor of 1.15. For pumps sold with motors, pumps sold with motors and continuous controls, or pumps sold with motors and non-continuous controls, the motor horsepower is the rated horsepower of the motor with which the pump is being tested.E. 1.2.1.2 Determine the default nominal full load motor efficiency as described in section III.E.1.2.1.2.1 of this appendix for ESCC, ESFM, IL, RSHES, RSHIL, RSV, and VT pumps; or section III.E.1.2.1.2.2. of this appendix for ST pumps; or section III.E.1.2.1.2.3 of this appendix for SVIL pumps.
E. 1.2.1.2.1. For ESCC, ESFM, IL, RSHES, RSHIL, RSV, and VT pumps, the default nominal full load motor efficiency is the minimum of the nominal full load motor efficiency standards (open or enclosed) from the table containing the current energy conservation standards for NEMA Design B motors at § 431.25 , with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower determined in section III.E.1.2.1.1 of this appendix.
E. 1.2.1.2.2. For ST pumps, prior to the compliance date of any energy conservation standards for submersible motors in subpart B of this part, the default nominal full load motor efficiency is the default nominal full load submersible motor efficiency listed in table 2 of this appendix, with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower determined in section III.E.1.2.1.1 of this appendix. Starting on the compliance date of any energy conservation standards for submersible motors in subpart B of this part, the default nominal full load motor efficiency is the minimum of any nominal full load motor efficiency standard from the table containing energy conservation standards for submersible motors in subpart B of this part, with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower determined in accordance with section III.E.1.2.1.1 of this appendix.
E. 1.2.1.2.3. For SVIL pumps, the default nominal full load motor efficiency is the minimum full load motor efficiency standard from the tables containing the current energy conservation standards for polyphase or CSCR/CSIR small electric motors at § 431.446 , with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower determined in section III.E.1.2.1.1 of this appendix, or for SVIL pumps sold with motors less than 0.25 hp, the default nominal full load motor efficiency is 58.3% for 6-pole, 64.6% for 4-pole, and 61.7% for 2-pole motors.
E. 1.2.2 Determine the loss factor at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Where:
yi = the part load loss factor at load point i,
Pi = pump power input to the bare pump at load point i (hp), as determined in accordance with section III.E.1.1 of this appendix,
MotorHP = as determined in accordance with section III.E.1.2.1 of this appendix (hp),
IV. Testing-Based Approach for Pumps Sold With Motors
A. Scope. This section IV applies only to pumps sold with electric motors (excluding pumps sold with inverter-only synchronous electric motors regulated by DOE's test procedure and/or energy conservation standards in subpart B of this part), including single-phase induction motors.
B. Measurement Equipment. The requirements regarding measurement equipment presented in section I.B of this appendix apply to this section IV. In addition, when testing pumps using a calibrated motor, electrical measurement equipment shall meet the requirements of section C.4.3 of HI 40.6-2021 (including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3 of HI 40.6), and motor power input shall be determined according to section 40.6.3.2.3 of HI 40.6-2021 and meet the requirements in Table 40.6.3.2.3 of HI 40.6-2021.
C. Test Conditions. The requirements regarding test conditions presented in section I.C of this appendix apply to this section IV. In addition, when testing pumps using a calibrated motor, the conditions in section C.4.3.1 of HI 40.6-2021, including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in Section C.4.3.1 of HI 40.6, shall be met.
D. Testing BEP for the Pump. Determine the best efficiency point (BEP) of the pump as follows:
D.
1. Adjust the flow by throttling the pump without changing the speed of rotation of the pump and conduct the test at a minimum of the following seven flow points: 40, 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate of the pump at the nominal speed of rotation, as specified in section 40.6.5.5.1 of HI 40.6-2021, including the applicable provisions of HI 9.6.1-2017 as referenced in section 40.6.5.5.1 of HI 40.6-2021.
D.2. Determine the BEP flow rate as the flow rate at the operating point of maximum pump efficiency on the pump efficiency curve, as determined in accordance with Section 40.6.6.3 of HI 40.6-2021, where the pump efficiency is the ratio of the pump power output divided by the pump power input, as specified in Table 40.6.2 of HI 40.6-2021, disregarding the calculations provided in section 40.6.6.2 of HI 40.6-2021.
E. Calculating the Constant Load Pump Energy Rating. Determine the PERCL of each tested pump using the following equation:
Where:
PERCL = the pump energy rating for a constant load (hp),
[OMEGA]i = 0.3333,
Piin = measured driver power input to the motor at load point i (hp) for the tested pump as determined in accordance with section IV.E.1 of this appendix, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
E. 1 Determine the driver power input at 75, 100, and 110 percent of the BEP flow rate by employing a least squares regression to determine a linear relationship between the driver power input at the nominal speed of rotation of the pump and the measured flow rate at the following load points: 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate. Use the linear relationship to determine the driver power input at the nominal speed of rotation for the load points of 75, 100, and 110 percent of the BEP flow rate.
V. Calculation-Based Approach for Pumps Sold With Motors
A. Scope. This section V can only be used in lieu of the test method in section IV of this appendix to calculate the index for pumps sold with motors listed in section V.A.1, V.A.2, or V.A.3 of this appendix.
A. 1 Pumps sold with motors subject to DOE's energy conservation standards for polyphase electric motors at § 431.25(g) ,
A. 2 SVIL pumps sold with small electric motors regulated by DOE's energy conservation standards at § 431.446 or with SNEMs regulated by DOE's test procedure and/or energy conservation standards in subpart B of this part but including motors of such varieties that are less than 0.25 hp, and
A.3. Pumps sold with submersible motors.
A.4. Pumps sold with motors not listed in sections V.A.1, V.A.2, or V.A.3 of this appendix cannot use this section V and must apply the test method in section IV of this appendix.
B. Measurement Equipment. The requirements regarding measurement equipment presented in section I.B of this appendix apply to this section V. In addition, when testing pumps using a calibrated motor, electrical measurement equipment shall meet the requirements of section C.4.3 of HI 40.6-2021 (including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3 of HI 40.6), and motor power input shall be determined according to section 40.6.3.2.3 of HI 40.6-2021 and meet the requirements in Table 40.6.3.2.3 of HI 40.6-2021.
C. Test Conditions. The requirements regarding test conditions presented in section I.C of this appendix apply to this section V. In addition, when testing pumps using a calibrated motor, the conditions in section C.4.3.1 of HI 40.6-2021, including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3.1 of HI 40.6-2021 shall be met.
D. Testing BEP for the Pump. Determine the best efficiency point (BEP) of the pump as follows:
D.
1. Adjust the flow by throttling the pump without changing the speed of rotation of the pump and conduct the test at a minimum of the following seven flow points: 40, 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate of the pump at the nominal speed of rotation, as specified in section 40.6.5.5.1 of HI 40.6-2021, including the applicable provisions of HI 9.6.1-2017 as referenced in section 40.6.5.5.1 of HI 40.6-2021.
D.2. Determine the BEP flow rate as the flow rate at the operating point of maximum pump efficiency on the pump efficiency curve, as determined in accordance with section 40.6.6.3 of HI 40.6-2021, where the pump efficiency is the ratio of the pump power output divided by the pump power input, as specified in Table 40.6.2 of HI 40.6-2021, disregarding the calculations provided in section 40.6.6.2 .
E. Calculating the Constant Load Pump Energy Rating. Determine the PERCL of each tested pump using the following equation:
Where:
PERCL = the pump energy rating for a constant load (hp),
[OMEGA]i = 0.3333,
Piin,m = calculated driver power input to the motor at load point i for the tested pump as determined in accordance with section V.E.1 of this appendix (hp), and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
E. 1 Determine the driver power input at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Where:
Piin,m = driver power input to the motor at load point i (hp),
Pi = pump power input to the bare pump at load point i, as determined in section V.E.1.1 of this appendix (hp),
Li = the part load motor losses at load point i as determined in accordance with section V.E.1.2 of this appendix (hp), and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
E. 1.1 Determine the pump power input at 75, 100, and 110 percent of the BEP flow rate by employing a least squares regression to determine a linear relationship between the pump power input at the nominal speed of rotation of the pump and the measured flow rate at the following load points: 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate. Use the linear relationship to determine the pump power input at the nominal speed of rotation for the load points of 75, 100, and 110 percent of the BEP flow rate.
E. 1.2 Determine the motor part load losses at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Li = Lfull * Yi
Where:
Li = motor losses at load point i (hp),
Lfull = motor losses at full load as determined in accordance with section V.E.1.2.1 of this appendix (hp),
yi = part load loss factor at load point i as determined in accordance with section V.E.1.2.2 of this appendix, and
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate.
E. 1.2.1 Determine the full load motor losses using the appropriate motor efficiency value and horsepower as shown in the following equation:
Where:
Lfull = motor losses at full load (hp),
MotorHP = the horsepower of the motor with which the pump model is being tested (hp), and
[ETA]motor,full = the represented nominal full load motor efficiency (i.e., nameplate/DOE-certified value) or default nominal full load submersible motor efficiency as determined in accordance with section V.E.1.2.1.1 of this appendix (%).
E. 1.2.1.1 For pumps sold with motors other than submersible motors, determine the represented nominal full load motor efficiency as described in section V.E.1.2.1.1.1 of this appendix. For pumps sold with submersible motors, determine the default nominal full load submersible motor efficiency as described in section V.E.1.2.1.1.2 of this appendix.
E. 1.2.1.1.1 For pumps sold with motors other than submersible motors, the represented nominal full load motor efficiency is that of the motor with which the given pump model is being tested, as determined in accordance with the DOE test procedure for electric motors at § 431.16 or, for SVIL, the DOE test procedure for small electric motors at § 431.444 , or the DOE test procedure for SNEMs in subpart B to this part, as applicable (including for motors less than 0.25 hp), and if available, applicable representation procedures in 10 CFR part 429 and this part.
E. 1.2.1.1.2 For pumps sold with submersible motors, prior to the compliance date of any energy conservation standards for submersible motors in subpart B of this part, the default nominal full load submersible motor efficiency is that listed in table 2 of this appendix, with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower of the pump being tested, or if a test procedure for submersible motors is provided in subpart B to this part, the represented nominal full load motor efficiency of the motor with which the given pump model is being tested, as determined in accordance with the applicable test procedure in subpart B to this part and applicable representation procedures in 10 CFR part 429 and this part, may be used instead. Starting on the compliance date of any energy conservation standards for submersible motors in subpart B of this part, the default nominal full load submersible motor efficiency may no longer be used. Instead, the represented nominal full load motor efficiency of the motor with which the given pump model is being tested, as determined in accordance with the applicable test procedure in subpart B of this part and applicable representation procedures in 10 CFR part 429 and this part, must be used.
E. 1.2.2 Determine the loss factor at each load point corresponding to 75, 100, or 110 percent of the BEP flow rate as follows:
Where:
yi = the part load loss factor at load point i,
Pi = the pump power input to the bare pump at load point i as determined in accordance with section V.E.1.1 of this appendix (hp),
MotorHP = the horsepower of the motor with which the pump model is being tested (hp),
i = load point corresponding to 75, 100, or 110 percent of the BEP flow rate, and
in the equation in this section V.E.1.2.2. of this appendix to calculate the part load loss factor at each load point
VI. Testing-Based Approach for Pumps Sold with Motors and Controls
A. Scope. This section VI applies only to pumps sold with electric motors, including single-phase induction motors, and continuous or non-continuous controls, as well as to pumps sold with inverter-only synchronous electric motors that are regulated by DOE's test procedure and/or energy conservation standards in subpart B of this part (with or without controls). For the purposes of this section VI, all references to "driver input power" in this section VI or HI 40.6-2021 refer to the input power to the continuous or non-continuous controls.
B. Measurement Equipment. The requirements regarding measurement equipment presented in section I.B of this appendix apply to this section VI. In addition, when testing pumps using a calibrated motor, electrical measurement equipment shall meet the requirements of section C.4.3 of HI 40.6-2021 (including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3 of HI 40.6), and motor power input shall be determined according to section 40.6.3.2.3 of HI 40.6-2021 and meet the requirements in Table 40.6.3.2.3 of HI 40.6-2021.
C. Test Conditions. The requirements regarding test conditions presented in section I.C of this appendix apply to this section VI. In addition, when testing pumps using a calibrated motor, the conditions in section C.4.3.1 of HI 40.6-2021, including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3.1 of HI 40.6, shall be met.
D. Testing BEP for the Pump. Determine the best efficiency point (BEP) of the pump as follows:
D.
1. Adjust the flow by throttling the pump without changing the speed of rotation of the pump and conduct the test at a minimum of the following seven flow points: 40, 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate of the pump at the nominal speed of rotation, as specified in section 40.6.5.5.1 of HI 40.6-2021, including the applicable provisions of HI 9.6.1-2017 as referenced in section 40.6.5.5.1 of HI 40.6-2021.
D.2. Determine the BEP flow rate as the flow rate at the operating point of maximum pump efficiency on the pump efficiency curve, as determined in accordance with section 40.6.6.3 of HI 40.6-2021, where the pump efficiency is the ratio of the pump power output divided by the pump power input, as specified in Table 40.6.2 of HI 40.6-2021, disregarding the calculations provided in section 40.6.6.2 .
E. Calculating the Variable Load Pump Energy Rating. Determine the PERVL of each tested pump using the following equation:
Where:
PERVL = the pump energy rating for a variable load (hp);
[OMEGA]i = 0.25;
Piin,c = the normalized driver power input to continuous or non-continuous controls at load point i for the tested pump as determined in accordance with section VI.E.1 of this appendix; and
i = load point corresponding 25, 50, 75, or 100 percent of the BEP flow rate.
E.
1. Determine the driver power input at 100 percent of the measured BEP flow rate of the tested pump by employing a least squares regression to determine a linear relationship between the measured driver power input at the nominal speed of rotation of the pump and the measured flow rate, using the following load points: 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate. Use the linear relationship to determine the driver power input at the nominal speed of rotation for the load point of 100 percent of the measured BEP flow rate of the tested pump.
E.2 Determine the driver power input at 25, 50, and 75 percent of the BEP flow rate by measuring the driver power input at the load points defined by:
(1) Those flow rates, and
(2) The associated head points calculated according to the following reference system curve equation:
Where:
Hi = pump total head at load point i (ft),
H100` = pump total head at 100 percent of the BEP flow rate and nominal speed of rotation (ft),
Qi = flow rate at load point i (gpm),
Q100` = flow rate at 100 percent of the BEP flow rate and nominal speed of rotation (gpm), and
i = load point corresponding to 25, 50, or 75 percent of the measured BEP flow rate of the tested pump.
E.2.1. For pumps sold with motors and continuous controls, the specific head and flow points must be achieved within 10 percent of the calculated values and the measured driver power input must be corrected to the exact intended head and flow conditions using the following equation:
Where:
Piin,c = the corrected driver power input to the continuous or non-continuous controls at load point i (hp),
Hsp,i = the specified total system head at load point i based on the reference system curve (ft),
HM,j = the measured total system head at load point j (ft),
Qsp,i = the specified total system flow rate at load point i based on the reference system curve (gpm),
QM,j = the measured total system flow rate at load point j (gpm),
PM,jin,c = the measured normalized driver power input to the continuous or non-continuous controls at load point j (hp),
i = specified load point at 25, 50, 75, or 100 percent of BEP flow, and
j = measured load point corresponding to specified load point i.
E.2.2. For pumps sold with motors and non-continuous controls, the head associated with each of the specified flow points shall be no lower than 10 percent below that defined by the reference system curve equation in section VI.E.2 of this appendix. Only the measured flow points must be achieved within 10 percent of the calculated values. Correct for flow and head as described in section VI.E.2.1, except do not correct measured head values that are higher than the reference system curve at the same flow rate; only correct flow rate and head values lower than the reference system curve at the same flow rate. For head values higher than the system curve, use the measured head points directly to calculate PEIVL.
VII. Calculation-Based Approach for Pumps Sold With Motors and Controls
A. Scope. This section VII can only be used in lieu of the test method in section VI of this appendix to calculate the index for pumps listed in sections VII.A.1, VII.A.2, VII.A.3, and VII.A.4 of this appendix.
A.
1. Pumps sold with motors regulated by DOE's energy conservation standards for polyphase NEMA Design B electric motors at § 431.25(g) and continuous controls,
A.
2. Pumps sold with inverter-only synchronous electric motors regulated by DOE's test procedure and/or energy conservation standards in subpart B of this part,
A.3. SVIL pumps sold with small electric motors regulated by DOE's energy conservation standards at § 431.446 or with SNEMs regulated by DOE's test procedure and/or energy conservation standards in subpart B of this part (but including motors of such varieties that are less than 0.25 hp) and continuous controls,
A.4. Pumps sold with submersible motors and continuous controls, and
A.5. Pumps sold with motors not listed in sections VII.A.1, VII.A.2, VII.A.3, and VII.A.4 of this appendix and pumps sold without continuous controls, including pumps sold with non-continuous controls, cannot use this section and must apply the test method in section VI of this appendix.
B. Measurement Equipment. The requirements regarding measurement equipment presented in section I.B of this appendix apply to this section VII. In addition, when testing pumps using a calibrated motor, electrical measurement equipment shall meet the requirements of section C.4.3 of HI 40.6-2021 (including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3 of HI 40.6), and motor power input shall be determined according to section 40.6.3.2.3 of HI 40.6-2021 and meet the requirements in Table 40.6.3.2.3 of HI 40.6-2021.
C. Test Conditions. The requirements regarding test conditions presented in section I.C of this appendix apply to this section VII. In addition, when testing pumps using a calibrated motor, the conditions in section C.4.3.1 of HI 40.6-2021, including the applicable provisions of CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, as referenced in section C.4.3.1 of HI 40.6-2021 shall be met.
D. Testing BEP for the Pump. Determine the best efficiency point (BEP) of the pump as follows:
D.
1. Adjust the flow by throttling the pump without changing the speed of rotation of the pump and conduct the test at a minimum of the following seven flow points: 40, 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate of the pump at the nominal speed of rotation, as specified in HI 40.6-2021, except section 40.6.5.3 , and appendix B, including the applicable provisions of HI 9.6.1-2017, HI 9.6.6-2016, HI 9.8-2018, HI 14.1-14.2-2019, the HI Engineering Data Book, ASME MFC-3M-2004, ASME MFC-5M-1985, ASME MFC-8M-2001, ASME MFC-12M-2006, ASME MFC-16-2014, ASME MFC-22-2007, AWWA E103-2015, CSA C390-10, IEEE 112-2017, IEEE 114-2010-A, ISO 1438:2017, ISO 2186:2007, ISO 2715:2017, ISO 3354:2008, ISO 3966:2020, ISO 5167-1:2003, ISO 5198:1987, ISO 6416:2017, and ISO 20456:2017, as referenced in HI 40.6-2021.
D.2. Determine the BEP flow rate as the flow rate at the operating point of maximum pump efficiency on the pump efficiency curve, as determined in accordance with section 40.6.6.3 of HI 40.6-2021, where the pump efficiency is the ratio of the pump power output divided by the pump power input, as specified in Table 40.6.2 of HI 40.6-2021, disregarding the calculations provided in section 40.6.6.2 .
E. Calculating the Variable Load Pump Energy Rating. Determine the PERVL of each tested pump using the following equation:
Where:
PERVL = the pump energy rating for a variable load (hp);
[OMEGA]i = 0.25;
Piin,c = the calculated driver power input to the continuous or non-continuous controls at load point i for the tested pump as determined in accordance with section VII.E.1 of this appendix; and
i = load point corresponding to 25, 50, 75, or 100 percent of the BEP flow rate.
E. 1 Determine the driver power input at each load point corresponding to 25, 50, 75, or 100 percent of the BEP flow rate as follows:
Where:
Piin,c = driver power input at to the continuous or non-continuous controls at load point i (hp),
Pi = pump power input to the bare pump at load point i as determined in accordance with section VII.E.1.1 of this appendix (hp),
Li = the part load motor and control losses at load point i as determined in accordance with section VII.E.1.2 of this appendix (hp), and
i = load point corresponding to 25, 50, 75, or 100 percent of the BEP flow rate.
E. 1.1 Determine the pump power input at 100 percent of the measured BEP flow rate of the tested pump by employing a least squares regression to determine a linear relationship between the measured pump power input at the nominal speed of rotation and the measured flow rate at the following load points: 60, 75, 90, 100, 110, and 120 percent of the expected BEP flow rate. Use the linear relationship to determine the pump power input at the nominal speed of rotation for the load point of 100 percent of the BEP flow rate.
E. 1.1.1 Determine the pump power input at 25, 50, and 75 percent of the BEP flow rate based on the measured pump power input at 100 percent of the BEP flow rate and using with the following equation:
Where:
Pi = pump power input at load point i (hp);
P100% = pump power input at 100 percent of the BEP flow rate and nominal speed of rotation (hp);
Qi = flow rate at load point i (gpm);
Q100% = flow rate at 100 percent of the BEP flow rate and nominal speed of rotation (gpm); and
i = load point corresponding to 25, 50, or 75 percent of the measured BEP flow rate of the tested pump.
E. 1.2 Calculate the motor and control part load losses at each load point corresponding to 25, 50, 75, and 100 percent of the BEP flow rate as follows:
Li = Lfull * zi
Where:
Li = motor and control losses at load point i (hp),
Lfull = motor losses at full load or, for inverter-only synchronous electric motors, motor + inverter losses at full load, as determined in accordance with section VII.E.1.2.1 of this appendix (hp),
zi = part load loss factor at load point i as determined in accordance with section VII.E.1.2.2 of this appendix, and
i = load point corresponding to 25, 50, 75, or 100 percent of the BEP flow rate.
E. 1.2.1 Determine the full load motor losses using the appropriate motor efficiency value and horsepower as shown in the following equation:
Where:
Lfull = motor losses at full load (hp), or for inverter-only synchronous electric motors, motor + inverter losses at full load,
MotorHP = the horsepower of the motor with which the pump model is being tested (hp), and
[ETA]motor,full = the represented nominal full load motor efficiency (i.e., nameplate/DOE-certified value) or the represented nominal full load motor + inverter efficiency or the default nominal full load submersible motor efficiency as determined in accordance with section VII.E.1.2.1.1 of this appendix (%).
E. 1.2.1.1 For pumps sold with motors other than inverter-only synchronous electric motors or submersible motors, determine the represented nominal full load motor efficiency as described in section VII.E.1.2.1.1.1 of this appendix. For pumps sold with inverter-only synchronous electric motors, determine the represented nominal full load motor + inverter efficiency as described in section VII.E.1.2.1.1.2 of this appendix. For pumps sold with submersible motors, determine the default nominal full load submersible motor efficiency as described in section VII.E.1.2.1.1.3 of this appendix.
E. 1.2.1.1.1 For pumps sold with motors other than inverter-only synchronous electric motors or submersible motors, the represented nominal full load motor efficiency is that of the motor with which the given pump model is being tested, as determined in accordance with the DOE test procedure for electric motors at § 431.16 or, for SVIL, the DOE test procedure for small electric motors at § 431.444 or the DOE test procedure for SNEMs in subpart B of this part, as applicable (including for motors less than 0.25 hp), and, if available, applicable representation procedures in 10 CFR part 429 and this part.
E. 1.2.1.1.2 For pumps sold with inverter-only synchronous electric motors, the represented nominal full load motor + inverter efficiency is that of the motor with which the given pump model is being tested, as determined in accordance with the DOE test procedure for inverter-only synchronous electric motors in subpart B of this part, and, if available, applicable representation procedures in 10 CFR part 429 and this part.
E. 1.2.1.1.3 For pumps sold with submersible motors, prior to the compliance date of any energy conservation standards for submersible motors in subpart B of this part, the default nominal full load submersible motor efficiency is that listed in table 2 of this appendix, with the number of poles relevant to the speed at which the pump is being tested (see section I.C.1 of this appendix) and the motor horsepower of the pump being tested, or if a test procedure for submersible motors is provided in subpart B of this part, the represented nominal full load motor efficiency of the motor with which the given pump model is being tested, as determined in accordance with the applicable test procedure in subpart B of this part and applicable representation procedures in 10 CFR part 429 and this part, may be used instead. Starting on the compliance date of any energy conservation standards for submersible motors in subpart B of this part, the default nominal full load submersible motor efficiency may no longer be used and instead the represented nominal full load motor efficiency of the motor with which the given pump model is being tested, as determined in accordance with the applicable test procedure in subpart B of this part and applicable representation procedures in 10 CFR part 429 and this part, must be used instead.
E. 1.2.2 For load points corresponding to 25, 50, 75, and 100 percent of the BEP flow rate, determine the part load loss factor at each load point as follows:
Where:
z i = the motor and control part load loss factor at load point i,
a,b,c = coefficients listed in either Table 4 of this appendix for induction motors or Table 5 of this appendix for inverter-only synchronous electric motors, based on the horsepower of the motor with which the pump is being tested,
Pi = the pump power input to the bare pump at load point i, as determined in accordance with section VII.E.1.1 of this appendix (hp),
MotorHP = the horsepower of the motor with which the pump is being tested (hp),
Table 2-Default Nominal Full Load Submersible Motor Efficiency by Motor Horsepower and Pole
| Motor horsepower (hp) | Default nominal full load submersible motor efficiency | ||
| 2 poles | 4 poles | 6 poles | |
| 1 | 55 | 68 | 64 |
| 1.5 | 66 | 70 | 72 |
| 2 | 68 | 70 | 74 |
| 3 | 70 | 75.5 | 75.5 |
| 5 | 74 | 75.5 | 75.5 |
| 7.5 | 68 | 74 | 72 |
| 10 | 70 | 74 | 72 |
| 15 | 72 | 75.5 | 74 |
| 20 | 72 | 77 | 74 |
| 25 | 74 | 78.5 | 77 |
| 30 | 77 | 80 | 78.5 |
| 40 | 78.5 | 81.5 | 81.5 |
| 50 | 80 | 82.5 | 81.5 |
| 60 | 81.5 | 84 | 82.5 |
| 75 | 81.5 | 85.5 | 82.5 |
| 100 | 81.5 | 84 | 82.5 |
| 125 | 84 | 84 | 82.5 |
| 150 | 84 | 85.5 | 85.5 |
| 200 | 85.5 | 86.5 | 85.5 |
| 250 | 86.5 | 86.5 | 85.5 |
Table 3-Nominal Full Load Motor Efficiency Values
| Nominal full load motor efficiency* |
| 50.5 |
| 52.5 |
| 55.0 |
| 57.5 |
| 59.5 |
| 62.0 |
| 64.0 |
| 66.0 |
| 68.0 |
| 70.0 |
| 72.0 |
| 74.0 |
| 75.5 |
| 77.0 |
| 78.5 |
| 80.0 |
| 81.5 |
| 82.5 |
| 84.0 |
| 85.5 |
| 86.5 |
| 87.5 |
| 88.5 |
| 89.5 |
| 90.2 |
| 91.0 |
| 91.7 |
| 92.4 |
| 93.0 |
| 93.6 |
| 94.1 |
| 94.5 |
| 95.0 |
| 95.4 |
| 95.8 |
| 96.2 |
| 96.5 |
| 96.8 |
| 97.1 |
| 97.4 |
| 97.6 |
| 97.8 |
| 98.0 |
| 98.2 |
| 98.4 |
| 98.5 |
| 98.6 |
| 98.7 |
| 98.8 |
| 98.9 |
| 99.0 |
* Note: Each consecutive incremental value of nominal efficiency represents one band.
Table 4-Induction Motor and Control Part Load Loss Factor Equation Coefficients for Section VII.E.1.2.2 of This Appendix A
| Motor horsepower (hp) | Coefficients for induction motor and control part load loss factor (zi) | ||
| a | b | c | |
| [LESS THAN EQUAL TO]5 | -0.4658 | 1.4965 | 0.5303 |
| [GREATER THAN]5 and [LESS THAN EQUAL TO]20 | -1.3198 | 2.9551 | 0.1052 |
| [GREATER THAN]20 and [LESS THAN EQUAL TO]50 | -1.5122 | 3.0777 | 0.1847 |
| [GREATER THAN]50 and [LESS THAN EQUAL TO]100 | -0.6629 | 2.1452 | 0.1952 |
| [GREATER THAN]100 | -0.7583 | 2.4538 | 0.2233 |
Table 5-Inverter-Only Synchronous Electric Motor and Control Part Load Loss Factor Equation Coefficients for Section VII.E.1.2.2 of This Appendix A
| Motor horsepower (hp) | Coefficients for induction motor and control part load loss factor (zi) | ||
| a | b | c | |
| [LESS THAN EQUAL TO]5 | -0.0898 | 1.0251 | 0.0667 |
| [GREATER THAN]5 and [LESS THAN EQUAL TO]20 | -0.1591 | 1.1683 | -0.0085 |
| [GREATER THAN]20 and [LESS THAN EQUAL TO]50 | -0.4071 | 1.4028 | 0.0055 |
| [GREATER THAN]50 and [LESS THAN EQUAL TO]100 | -0.3341 | 1.3377 | -0.0023 |
| [GREATER THAN]100 | -0.0749 | 1.0864 | -0.0096 |
10 C.F.R. 431 app A to Subpart Y of Part 431