Singapore June 2012

Agenda
1. Pump Configurations & Installations
2. Variable Speed Pump Basics
3. ASHRAE 90.1 requirements for

Variable Speed Pumping and

Balancing
4. All Variable Speed Chilled Water
Plant Control Methodology

Singapore June 2012

Pump types

Vertical Inline

Horizontal Split Case

End Suction

Singapore June 2012

Vertical InLine - 14x14x15 150hp

Easy to install
Pipe mounted directly into
piping - Smallest footprint
is inherent

Eliminate cost of

flex connections
and inertia bases
Minimal
commissioning
costs
Self contained unit
No site grouting costs
No alignment costs or

concerns

No lubrication

Suction
Diffuser

Triple Duty
Valve

required or seal
adjustments
necessary
No Pump Bearings

Singapore June 2012

4300 - 14x14x15 150hp

Pressure
Gauge

Sight Glass & Filter

Singapore June 2012

Vertical Inline Grooved Systems

20x20x19 Pump
Pipe Line Mounted & Supported
Inertia Base Not Required
Flex Connectors Not Required
No Alignment Required

1 Mechanical Seal to Maintain

Singapore June 2012

Primary CHW Pumps

Singapore June 2012

Condenser Pumps

Singapore June 2012

Dedicated Pump For Chillers

GuangHui Project Taiwan 60 000 tons of refrigeration

46-16x16x15 300 hp
23 -3000 ton Chiller installation
8

Singapore June 2012

Dedicated Pump - Chillers

Singapore June 2012

Ford Plant in Mexico

10

Singapore June 2012

Dual Pumps Typical Mounting

Seismic Installation

Singapore June 2012

Flotrex & Suction Guides

Singapore June 2012

Triple Duty Valve

Drip-tight Shut Off Valve

Flow Throttling Valve

The Armstrong Flo-Trex valve is designed

and tested for drip-tight isolation at
150% of maximum working pressure.

The Armstrong Flo-Trex valve uses a plug and disc

design which is the most effective valve type for
combining throttling of flow and isolation. Other
design valves may be effective for throttling or
isolation, but not both

Non-slam Check Valve

The Armstrong Flo-Trex valve incorporates a spring
closure design that closes the valve in a controlled
manner, protecting the valve from slamming due to
a reversal in flow caused by gravity or recirculation
from a parallel pump.

Convertible Body Design

The Armstrong Flo-Trex convertible body design
permits the valve to be changed on-site from
straight to angle configuration

Singapore June 2012

Suction Guide
90Elbow

Inline Strainer

Mounting the Suction Guide on any pump

Suction turns the piping 90, replacing an
elbow. In addition, the Suction Guide can be
rotated to any position allowed by the pump
suction bolts, from vertical to horizontal.

The stainless steel strainer has free area of at least

250% of pipe sectional area. A disposable finemesh
strainer is installed for start-up.

Reducing Elbow
The Suction Guide connects same size piping to
the pump suction, but can also connect to inlet
piping one size larger than the pump suction,
eliminating a reducing elbow.

Guide Vanes
Flow stabilizing vanes on the outlet allow the Suction
Guide to bolt directly to the pump, saving the space
and cost of a long straight pipe

Singapore June 2012

Vertical Inline Mechanical Seal Removal

Singapore June 2012

End SuctionBase Mounted

Pump
A comprehensive range of single stage,
end suction, radially-split centrifugal
pumps designed for a wide variety of
applications.
Features
self-venting
casing to prevent air binding, heavy duty
bearings that are sealed and lubricated
for life, back pull-out bearing frame for
easy
removal,
and
self-lubricating
mechanical seal to prevent liquid
seepage. Available in bronze fitted, all
bronze and all iron construction.

Singapore June 2012

4030 Base Mounted Pump Cross Sectional View

ANSI flanges.

Top centerline discharge

ANSI style casing, self
venting to eliminate
pump vapor lock

Drilled and tapped connections

for gauges and drain.

Radially split casing provides pull out design

that allows removal of bearing assembly and
impeller without disturbing pipe connections.

Gasket, non-asbestos,
confined as
recommended by ANSI.

Dynamically
balanced
cast bronze or
iron impeller

Bearing assembly
two anti-friction bearings,
permanently lubricated,
carry design loads with
minimum.

Stainless steel
Shaft Sleeve
Single spring mechanical seal with O-ring
mounted silicone carbide seat provides
leak-proof operation throughout pump range.

A heavy fabricated steel baseplate, rigidly constructed to ANSI/HI 1.3.5

standards, provides for proper alignment of pump and motor.
Base supported casing
eliminates need to support
casing when bearing
assembly is removed

Singapore June 2012

Base Mounted Pumps Base, Grouting & Alignment

Alignment

Base
Grouting

Singapore June 2012

Base Mounted Pumps Flex Connectors

Flexible Connectors

Straight Section
5 to 10 Pipe Dia.

Singapore June 2012

Hillcrest Recreation Center

Singapore June 2012

Base Mounted Pumps Concrete Base & Spring Isolators

Form for Concrete
Base

Spring Isolators

Singapore June 2012

COMMERCIAL PUMPS Model 4600 HSC

The Series 4600 is the state of the art
Horizontal Split Case pump based on the
"Tilted Parting" concept to minimize
turbulence at the eye of the impeller by its
straight
laminar
approach,
thus
maximizing efficiency. This also results in
the lowest profile and minimum floor
space of any HSC pump, lowering
installation costs. Cartridge seals and
bearing removal nuts ensure ease of
maintenance.

Singapore June 2012

COMMERCIAL PUMPS Model 4600 HSC

Singapore June 2012

COMMERCIAL PUMPS Model 4600 HSC

Double Suction Pumps

require approx. 30%
more space
Inertia Bases
Alignment
Grouting of bases
Vertical In Lines cost
less

Singapore June 2012

Typical HSC Installation

Singapore June 2012

Variable Speed Pumping

Presented By Rocco Logozzo S.A.Armstrong Limited

Singapore June 2012

How a pump works

Vertical inline pump

Singapore June 2012

Centrifugal Pump Characteristics

Design Duty

Head

BHP =______________
GPM x Head (ft)

Power

3960 x Pump Eff. %

Efficiency

KW = BHP x .746

Flow

Pump Basics Pump Selection

Singapore June 2012

For conditions of 1000 USGPM at 100 Ft a 4300 6x6x11.5 may be

used with a 40 HP motor 11.36 impeller diameter

Note that this is maximum non-overloading

impeller diameter for 40 HPmotor

Singapore June 2012

Why Variable Speed Pumping?

Singapore June 2012

The Cube Law

HP

The power consumed = Speed

Nominal
Power
Energy used
at rated speed.

Speed/Flow

Nominal
flow

Singapore June 2012

The Cube Law

Kw.

The power consumed = Speed

Nominal
Power

22 Kw pump at 50% of rated speed

Power = 22 Kw x (0.5 x 0.5 x 0.5)

12.75%
Energy Used
50% flow

Power = 2.75 Kw (12.25% nominal)

Speed/Flow
50%

Nominal
flow

Singapore June 2012

Fixed Speed Pumping

Singapore June 2012

Fixed Speed Pumping

Typical Secondary Pumping Loop (Constant Flow)

Singapore June 2012

Fixed Speed Pumping

DESIGN CONDITIONS: 1000 GPM @ 100 Feet

63 L/s @ 30.5 Meters

Singapore June 2012

Fixed Speed Pumping

Constant Flow System to Variable Flow System

Singapore June 2012

Power Savings: Flow @ 50% (Constant Speed Pump)

OPERATION POINT: 500 GPM @ 122 Feet

31.54 L/s @ 37 Meters

Singapore June 2012

Power Savings: Flow @ 50% (Constant Speed Pump)

Usgpm
1000
500

Pump
Ft. Hd
Power HP Efficiency
RPM
100
1760
31.3
80.7
122
1760
22.5
68.9
Power Savings:
28%

Singapore June 2012

Variable Speed Pumping

Singapore June 2012

Variable Speed Pumping

Typical Strategy 1 Constant head at
pump for Secondary Pumping Loop

Basic Requirements
1. Pumps
2. VFDs
3. DPS (Differential Pressure Sensor)
4. DPS Set Point *
*Depends where its located in the
the system
If its close to the pumps supply &
Return, the set point would be same as
the pumps differential pressure.

Singapore June 2012

Flow @ 50% DP Sensor across pump (100 Ft)

DP Set Point = 100 ft (298 KPA

OPERATING POINT: 500 GPM@ 100 Ft

Singapore June 2012

Power Savings: Flow @ 50% DP Sensor across pump

Usgpm
1000
500

Pump
Ft. Hd
Power HP Efficiency
RPM
100
1760
31.3
80.7
100
1599
17.5
72.0
Power Savings:
44%

Additional Savings over riding pump curve: 22%

Singapore June 2012

Variable Speed Pumping

Typical Strategy 2 Constant Head at Index

Point for Secondary Pumping Loop

What is the DP set point

if the sensor is located further
away from the pumps?

Singapore June 2012

Flow @ 50% DP Sensor across coil & CV

OPERATING POINT: 500 GPM @ 63 ft

31.54 L/s @ 188 KPa

Singapore June 2012

Variable Speed Pumping

Power Savings: Flow @ 50%
DP Sensor across coil & CV
Usgpm
1000
500

Pump
Ft. Hd
Power HP Efficiency
RPM
100
1760
31.3
80.7
63
1288
10.2
78.2
Power Savings:
67%

Additional Savings over maintaining plant DP: 42%

Singapore June 2012

Typical Strategy 3 DP Sensor across the Control Valve

DP Sensor located at the farthest point

sometimes called the Index leg
Problems could result where coils are
under flowed during part Load
How do we solve or mitigate this
Problem?
1) Multiple sensors
2) Manual Balancing with DP Controller
3) PICV Valves

Singapore June 2012

Flow @ 50% DP Sensor across CV

OPERATING POINT: 500 GPM @ 48 FT

Singapore June 2012

Power Savings: Flow @ 50% DP Sensor across CV (30 ft)

Usgpm
1000
500

Pump
Power HP Efficiency
RPM
100
1760
31.3
80.7
48
1141
7.5
80.4
Power Savings:
76%

Ft. Hd

Singapore June 2012

Variable Speed Pumping

Power Savings - Summary
System
Type
Constant
Variable
Variable
Variable
Variable

Pump
Sensor
Usgpm
Speed
Location
Constant
None
1000
Constant
None
500
Variable
Pump
500
Variable Load&CV 500
Variable
Valve
500

Ft. Hd
100
122
100
63
48

Pump
RPM
1760
1760
1599
1288
1141

Power HP Efficiency
31.3
22.5
17.5
10.2
7.5

80.7
68.7
72.0
78.2
80.4

Power
Savings
0%
28%
44%
67%
76%

Singapore June 2012

6.7.2.3 System Balancing

6.7.2.3.3 Hydronic System Balancing
All HVAC systems shall be balanced

Written balancing report for conditioned areas exceeding 5,000ft 2

(500m2)
Hydronic Systems shall be Proportionately Balanced in a manner to

first minimize throttling losses

Singapore June 2012

Unbalanced System
OA = 100F
A needlessly large volume

is pumped. This increases

the energy consumption at
both the pump and chiller

T = 20F
GPM

93F / 30% BTU

15

#1
T = 18F

89F / 45% BTU

25

#2
T = 14F

The return water

temperature is quite low.

This reduces the efficiency.
It also reduces the capacity
of the chiller to 79%

83F / 70% BTU

#3
T = 10F

75F / 100% BTU

100

#4
T = 6F

70F / 120% BTU

200

#5
T = 3.5F

A 250 Ton chiller is used,

but it supplies only 197.5

Ton (79%).

50

400

#6

65F / 140% BTU

45F

T = 6F
CHILLER
79%

65

F
63

F
64
59

F
61
55
58

51
54

48.5

51

790 GPM

**

51F

***

CONTROLLER

250 TON
CHILLER
197.5

Singapore June 2012

Balanced System

OA = 100F

T = 10F

GPM

75F / 100% BTU

100

The correct volume is

pumped and no more

pump energy than
necessary is used

T = 10F

75F / 100% BTU

100

75F / 100% BTU

temperature is
accomplished. Efficiency is
improved. 100% capacity
can be provided.

75F / 100% BTU

100

75F / 100% BTU

55
F
55

F
55

#5
T = 10F

100

#4
T = 10F

100

55

#3
T = 10F

The design return water

#2
T = 10F

100

55

#1

#6

F
55
F

75F / 100% BTU

The capacity of the chiller

is utilized to 100%.

45F

T = 10F
CHILLER
100%

600 GPM

**

55F

***

CONTROLLER

250 TON
CHILLER
(250)

Singapore June 2012

Typical Strategy 3 DP Sensor across the Control Valve

DP Sensor located at the farthest point

sometimes called the Index leg
Problems could result where coils are
under flowed during part Load
How do we solve or mitigate this
problem.
1) Multiple sensors or move sensor closer
2) Manual Balancing with DP Controller
3) PICV Valves

Singapore June 2012

Differential Pressure Controller

Protect Control Valves from large differential pressure variations

experienced at varying load on the system
Good Control Valve Authority is maintained at part load

Singapore June 2012

PICV Pressure Independent Control Valve

Standard EQM control valve

PICV

Singapore June 2012

DE IVS: Sensorless Pump Control & Design Envelope

Singapore June 2012

Design Envelop HVAC Pumping

Pumping unit complete with motor integrated VFD
and controls
Simply wire power as any pumping unit
Motors will not overload Controls allow max
motor nameplate current only
Supplied with 208V, 230V, 380V, 460V or
575V, ODP or TEFC motors
Available with Sensorless control
Sensorless feature can be disabled &
controlled through an Pump Controller, or BAS
via all common communication protocols

Singapore June 2012

Evolving
Brand1

Brand 2

Brand 3

Brand 4

Brand 5

Singapore June 2012

Sensorless Pump & Motor Data

Singapore June 2012

Sensorless Control
Pump & VFD units are supplied with Sensorless

Control as standard, where available

Sensorless Control may be switched at the factory [or
on-site] to another control strategy (BMS, Pump
Controller & remote sensor, etc)
Keys to Sensorless Control are:
Knowing where the pump is operating
Knowing where the pump should be operating

Singapore June 2012

Sensorless Control

Knowing where the pump is operating

How do we do that?

Singapore June 2012

Pump curve derived from pump test

Singapore June 2012

Flow / head requirements predict power & efficiency at rated speed

7500gpm at 45 m design
242.08hp at 86.83% efficiency

Singapore June 2012

Flow / head predicted from power & speed

240.35bhp at 58.8Hz
indicates unit operating at 7500gpm at 45 m head

Singapore June 2012

Design Envelope & Sensorless Control

Knowing where the pump should be operating

Singapore June 2012

Design Envelope IVS Where it should operate

Head

Cooling coil
with DP sensor

Design Speed

Operating curve for

temperature control

Min. Head

B
System

Pumps

A
B

Design Point
Minimum Head

Flow
Minimum Head equates to sensor setting at remote cooling coil in traditional system

Singapore June 2012

Head

Design
Envelope Pump
Sensorless
Control
IVS Sensorless
Technology

Original System
Curve

S2
S1 Operating Speed pump
curve

2
Control Curve
S2

S2 System Curve

S1

S1 System Curve

Power

12 Satisfied Flow & Head

Operating Point (S2
(S1 System
Curve)

P1 Power at current flow &

P2
head

How do we get from 1 to 2?

P1
P2

Traditional
Operating point is wherever pump
performance curve intersects
system resistance curve

Flow
Sensorless Control
Operating point is where pump
performance, system resistance and
control curves converge

Singapore June 2012

Design
Envelope Pump
Sensorless
Control
IVS Sensorless
Technology

Original System
Curve

1
S2 System Curve

2
S1 System Curve

How do we get from 1 to 2?

Speed is stable at 1 until system
control valves (CV) modulate.
System has CV modulating closed
resulting in a steeper S2 system
curve
Operating point begins to move to
the left from 1 on S1 speed curve;
power reduces as it does so;
incorrect speed for the new power
value is recognized immediately;
Sensorless reduces speed and
S1
chases equilibrium down control
curve until correct power & speed
ratio stabilizes at the new S2
system curve at 2 (S2 speed curve)
Reverses as CVs open
S2

Singapore June 2012

Variable Speed Paradigm Shift

Pump Performance
Curve Full Speed

Head

Operating Point

Motor
Power Line

Capability Envelope
As-built system:
System losses lower than
design Motor cannot
overload. Operates at speeds
at or below motor current limit

Pump Performance
Curve Design Speed

Design
Point

PUMP
OPERATING
CURVE

As-Built
System

Minimum
System Pressure
(Typical Sensor
Setting)

Part
Load
System Curves
Varies with load valves

Flow

Part load system needs

Higher Efficiency than
constant speed. Lower
system pressure allows load
valves to operate in design
diff pressure range

Singapore June 2012

Optimized capacity and motor power

Impeller trim is optimized to the motor power

53.5 lps @ 27 m
18.5 kW vs. 22 kW traditional

Electronic load limiting

Savings in smaller
motor & controls
Motor/integrated
controls = 350 or 9%
Power wiring = 40
Harmonics = 16.6% reduction

BEP
A
C
B

15 kW

30 kW

B Pump with Integrated VFD

(18.5 kW)

C Traditional pump (22 kW)

22 kW
18.5 kW

Singapore June 2012

Design Envelope advantages

Envelope selection reduces risk and cost

A Original design
B 2nd design
B

C Final design

Singapore June 2012

Energy Metering Capability

Use the Integrated Controls as an energy meter for energy
measurement verification

kWh
readout

Singapore June 2012

Flow Display
Flow meter savings
Ability for digital flow readout and communication to

BMS
More capabilities coming in future

Singapore June 2012

Wall Space Savings

No room
on wall
for multiple
VFDs

Singapore June 2012

Reflected Wave Voltage

If distance between the motor and the control is long, a

standing wave can form between the motor and control

These waves can increase voltage at the motor terminals

causing the motor insulation and bearings to fail prematurely

Locating the control with the motor will minimize this

problem

Singapore June 2012

Harmonics - What is it?

Singapore June 2012

Harmonic distortion

Voltage distortion
Summation of all
harmonic frequencies

may cause sensitive

loads to
malfunction

Current distortion
causes heat in the
transformer and its
power lines

Fundamental

Singapore June 2012

Harmonic Causes

Singapore June 2012

Harmonic Solutions

Singapore June 2012

Harmonic Solutions

Singapore June 2012

Harmonic distortion

IEEE 519-1992 is a standard for limiting harmonics

Measured at Point of Common Coupling (PCC)
Stricter limits at higher voltage
Prevent one customer from harming another
Not intended to be applied within a users system

Singapore June 2012

Harmonic Distortion
DC Link Reactors
built into IVS controls

Singapore June 2012

Harmonic Distortion
5HP

Variable Speed Drives with built-

in DC line reactors (equivalent to

5% AC line reactors)

Other drives often need external

AC reactors (for 30 HP estimated

cost is $440): Mitsubishi, Hitachi,
Lenze/AC Tech, Yaskawa*,
Schneider, Eaton*, Siemens

125HP

External AC line reactors

* Some models only

Singapore June 2012

Emission and immunity requirements

Design Envelope IVS pumps include RFI filters to

ensure compliance to low emission and

immunity requirements EN61800-3 to the 1st
environment class CI (EN55011 unrestricted
sales class B).
Wall-mounted drives often do not include these

and must be provided as an extra.

Singapore June 2012

CHW Retrofit Installation

Singapore June 2012

MLCC Project Boiler Retrofit

Singapore June 2012

Kings Yard Energy Center

Kings Yard Energy Centre / Olympic Park

London, UK

Singapore June 2012

(HES with VFD vs. VIL with VFD

Wiring required between VFD
& Disconnect Switch & Motor
Mounting Bracket for VFD or
labor
Sensors or Installation
Required
Pump Inertia Base & Grouting
Installation
Alignment
Flex Connectors

Singapore June 2012

All-Variable speed CHW plants

Singapore June 2012

Primary Secondary Pumping

Common Pipe: Sizing is very Important

L o a d S yste m

Primary Pumps should not interact with

Secondary Pumps.
Primary & Secondary side must
both be balanced
S e co n d a ry P u m p s

S u p p ly

S o u rce S yste m
C
H
I
L
L
E
R

C
H
I
L
L
E
R

C
H
I
L
L
E
R

D istrib u tio n
P rim a ryS e co n d a ry
C om m on

S yste m

R e tu rn

E xp a n sio n S yste m
P rim a ry P u m p s

Singapore June 2012

Variable Primary Plant Layout

Singapore June 2012

CHW Plant Basic Design

Systems have operated for

decades in these modes.

B u ild in g L o a d

Traditionally equipment has

been sized for the best
efficiency at full load, or
design day conditions.

Condenser
W a te r L o o p

C o o lin g T o w e r
C h ille d W a te r P u m p

Lets consider in detail the

operation of each of the
active components to better
understand how we could
save energy.

C h ille r
Condenser
W a te r P u m p

C h ille d W a te r L o o p

Singapore June 2012

CHW Plant Basic Design

B u ild in g L o a d

PID LOOP
Condenser
W a te r L o o p

C o o lin g T o w e r
C h ille d W a te r P u m p

PID LOOP

C h ille r
Condenser
W a te r P u m p

PID LOOP

C h ille d W a te r L o o p

Three PID Loops, behaving independently.

Capacity based sequencing.
Complex reset for strategies for light load.

Singapore June 2012

Typical Chiller Design

Chiller (Refrigerant Loop)
Traditional constant speed
chillers have a fixed
speed compressor. The
expansion control valve
adjusts to modulate the
amount of refrigeration
work to achieve a
setpoint chilled water
supply temperature.

Heat energy moves naturally from a warm to cooler medium. To move heat
energy from a cooler medium to a warmer medium requires external work,
these devices are referred to as refrigeration devices, in our industry we know
them as Chillers.
Compressor bearings require
lubricant = oil management
systems
T yp ic a l C e n trifu g a l C h ille r S c h e m a tic
C o m p re s s o r

Q (o u t to to w e r)

54F

C ondenser
(h ig h T , H i P )

E va p o ra to r (L o w T ,
Low P)

44F
Q (in fro m lo a d C H W )

E x p a n s io n V a lve

Singapore June 2012

All-Variable speed CHW plants

Decrease Condenser Temperature Condenser Relief

Increase Chilled Water Supply CHW Reset
Stage Chillers, Pumps, Towers & Tower Fans

Variable Speed Devices are More Efficient at

Part Load by Design Intent
Constant speed

Variable speed

Singapore June 2012

Singapore June 2012

"Natural Curve"
of VS Centrifugal Chiller
"Natural Curve" of a
Chiller
To achieve optimum
performance, chillers
should be
sequenced such that
the on-line chillers
operate as close as
possible to their
Natural Curve.

Singapore June 2012

Cooling Tower Basics

Cooling Tower
Rejects heat to atmosphere

through evaporative cooling

Water air exposure maximized
by panels and fans
Water molecules passing
through phase change to
vapor phase take heat energy
molecules remaining in
liquid phase give up heat
energy to phase change =
cooling of liquid

Singapore June 2012

Tower ETW Approach Temperature For 3 Tower Systems

Natural Curve
Effect with Variable Flow and Fan Speed Tower

The total power to fans

and pumps is the
same for the variable
speed and constant
speed systems at each
condition. Note the
improved approach by
slowing, not shedding
towers at low loads.

Singapore June 2012

Optimizing All-Variable Speed Configurations:

The "Equal Marginal Performance Principle"

Trade off equipment loading in one device to pick up more load on

another, and achieve the same net kW cooling for lower kW electrical
input.

Singapore June 2012

Equal Marginal Performance Principal

Singapore June 2012

Demand Based Control

Singapore June 2012

Plant KW/Ton measured in real time

Singapore June 2012

Chiller and Tower recommendations

The lower the turn down capability of each device, the

greater the efficiency of the plant.

The variable speed chiller should have 70% load
turndown and includes serial communication (Lonworks,
BACnet, Modbus, or P Lan .
The cooling towers must be selected for a 40% or greater
flow turndown

Singapore June 2012