This seminar is being brought to you by:

ASHRAE, Singapore Chapter &

Xylem, Bell & Gossett
Variable Speed Pumping in
Large Chilled Water Plants

Presented by:
Larry Konopacz, Manager of Training & Education
Bell & Gossett Little Red Schoolhouse
Thursday, October 22, 2015
Key Learning Objectives:
#1: Discuss the key design differences between
Primary/Secondary, Primary/Secondary/Tertiary, and
Variable Flow Primary large chilled water pumping
systems. Discuss the benefits and concerns related to
each of these key differences.

#2: Provide an overview and fundamental understanding

of how large chilled water variable speed pumping
systems operate and reduce energy consumption.
Discuss the theory behind the control curve and the
operation of the system within a control area.

#3: Compare expected energy savings based on

alternative locations for the sensors as well as sensorless
control. Also show how sensor location may result in
underflow conditions in zones without sensors.
Large Chilled Water Design Seminar
Primary-Secondary Pumping
Pump Selection – Worst Case Situation

Very
high
head
loss

Pump is selected for:

Sum of all terminal flow requirements
Highest head loss circuit
Another Problem – Variable Volume Systems

If all the control valves close, flow through the

source becomes too low or changes to quickly.
How can we separate a large
system into
“flow independent”
sub-systems?
Primary – Secondary Pumping
Fundamental Idea

Secondary
Pump

Tee Tee
Primary “A” “B”
Pump
Low pressure drop in the “common pipe”
Primary-Secondary Pumping
The idea is based on:

– Conservation of Mass

– Conservation of Energy
 Law of the Tee: Diversion

50 GPM

50 GPM
100 GPM
 Law of the Tee: Mixing

100 GPM

60 GPM 40 GPM
 No Secondary Flow

Secondary
Pump
Off

A B
100 GPM @ 45°F
100 GPM @ 45°F 100 GPM @ 45°F
Primary
Pump
 Primary = Secondary

100 GPM @ 45°F 100 GPM @ 55°F

Pump On

A B
100 GPM @ 45°F 100 GPM @ 55°F
0 GPM
 Primary > Secondary

50 GPM @ 45°F 50 GPM @ 55°F

Pump On Mixing at Tee B

A B
100 GPM @ 45°F 100 GPM @ 50°F
50 GPM @ 45°F
 Primary < Secondary

200 GPM @ 50°F 200 GPM @ 55°F

Pump On

A B
100 GPM @ 45°F 100 GPM @ 55°F
100 GPM @55F
Mixing at Tee A
Control Valve in Secondary

Two-way Valve
If Primary Flow = Secondary Flow
No flow in the common
Primary Supply Temp = Secondary Supply Temp
Primary Return Temp = Secondary Return Temp
If Primary Flow > Secondary Flow
“Forward” flow in the common
Primary Supply Temp = Secondary Supply Temp
Primary Return Temp ≠ Secondary Return Temp
If Primary Flow < Secondary Flow
“Backward” flow in the common
Primary Supply ≠ Secondary Supply
Primary Return = Secondary Return
 Primary-Secondary Pumping
Secondary Loop
Distribution

Primary Loop
Production
Supply

C C C
H H H Pump
I I I Controller
L L L
L L L
E E E
R R R
Adjustable Freq. Drives
Primary-Secondary
Common Pipe
Return
 Secondary System Curve
Control Valves
Closing

H3
H2
Control Valves
H1
Valve Opening
Throttling
Head

System
Curve

F3 F2 F1
Flow
Large Chilled Water Design Seminar
Variable Speed Pumping
 Why variable speed?

1. How does it work?

2. When should I use it?
3. What about variable primary flow?
 Adjustable Frequency Drives
• Rectifier section
– converts AC to DC
• Inverter section
– forms a synthetic sine wave
– maintains a controlled frequency/voltage ratio

• Requires an automatic control system

• Adds to the initial cost of the system

 Affinity Laws
1. Capacity varies as the RPM change ratio:

FLOW 2 = FLOW 1 ( SPEED2 / SPEED 1)

2. Head varies as the square of the RPM change ratio:

2
HEAD 2 = HEAD 1 (SPEED 2 / SPEED 1)

3. Brake horsepower varies as the cube of the RPM change ratio:

3
BHP 2 = BHP 1 (SPEED 2 / SPEED 1)
 Theoretical Savings
120 120
Pump Curves 100% Speed
110 110
100 90% 100
Design
90 90
80 80% Head 80

70 70
% Head

% BHP
60 70% 60

50 60% 50

40 HP Draw 40
50%
30 30
Head
20 40% 20
BHP
10 30% 10
Flow
0 0
0 10 20 30 40 50 60 70 80 90 100
% Design Flow
Required Differential Pressure

P Sensor/Transmitter
25 Ft. Head
 System Curve
& V/S Control System
110

100 25 FT Differential Head

Maintained Across Load Set Point
80 (Set Point)
Head

Pump TDH
60
Overall
40 system curve
Distribution
20 piping head
loss curve
0
0 200 400 600 800 1000 1200 1400 1600
Flow
 Effect of Constant* Set Point
110
As the valve closes,
100 the pump slows down
Set point,
Control curve
80 25 FT
Head

Pump TDH
60
Overall system curve

40
Distribution
20 piping head
loss curve

0
0 200 400 600 800 1000 1200 1400 1600
Flow

*What’s Constant?
 Pump Control Curve
Initial Speed
B
A

Head, H
(feet)
Pipe, Fitting
Friction Loss

Q2 Q1
Flow, Q
(gpm)
Decrease in Heat Load Results in Troom < T set point
Causes Two Way Valves to Throttle Flow
 Pump
Curve Speed 1
B Control Curve
A
Speed 2

Head, H C
(feet)
Pipe, Fitting
Friction Loss

Q3 Q2 Q1
Flow, Q
(gpm)

Decrease in Pump Speed Reduces Flow, Reduces Error

 Control Curve
Speed 1
B
A

Head
(ft) Pipe, Fitting
Final Speed C Friction Loss

Flow, Q Q4 Q1
(gpm)

System Operation on Control Curve at Lower Speed

 Variable vs Constant Head Loss
Constant Differential Head Loss

Variable Head Loss

Supply

C C C
H H H Pump
I I I Controller
L L L
L L L
E E E
R R R
Adjustable Freqy. Drives

Return
 Variable Head Loss Ratio
C/S, Constant Flow System Pump Head Matched to
Base 100 System at Design Flow
90

80 C/S, Variable Flow

V/S, 0% Variable Hd Loss, 100% Constant Hd
Percent Design BHP

70
V/S, 25% Variable Hd Loss, 75% Constant Hd
60
50
V/S, 50% Variable Hd Loss, 50% Constant Hd
40
V/S, 75% Variable Hd Loss, 25% Constant Hd
30
20 V/S, 100% Variable Hd Loss, 0% Constant Hd

10

0 10 20 30 40 50 60 70 80 90 100
% Flow
 V/S Curves
120 50 % 60 % 70 %
80 % 85 % % Efficiency
110 85 %
80 %
100 100 %
90

80 90 %
Head, Feet

70
% Speed Curves
60 80 %
Constant
50 Efficiency
70 %
Curve
40
60 %
30
50%
20
40 %
10 30 %
GPM
0
0 100 200 300 400 500 600 700 800 900 1000
Efficiency Changes
120
50 % 60 % 70 % 80 % % Efficiency
85 %
110 85 %
80 %
100 100 %
90

80 90 %
Head, Feet

70 % Speed Curves
80 %
60
Constant
50 70 % Efficiency
Curve
40
60 %
30
50%
20
40 %
10 30 %
GPM
0
0 100 200 300 400 500 600 700 800 900 1000
Minimum Drive Speed
120
50 % 60 % 70 % 80 % % Efficiency
85 %
110 85 %
80 %
100 100 %
90

80 90 %
Head, Feet

70 % Speed Curves
80 %
60
Constant
50 70 % Efficiency
Curve
40
60 %
30
50%
20
40 %
10 30 %
GPM
0
0 100 200 300 400 500 600 700 800 900 1000
Multiple Pump System
Constant Differential Head Loss

Variable Head Loss

Supply

C C C
H H H Pump
I I I Controller
L L L
L L L
E E E
R R R
Adjustable Freqy. Drives

Return
Parallel V/S Operation

Pump 1

Pumps 1 & 2 Pumps 1, 2 & 3

Control Curve 1770 RPM

1450 RPM

1150 RPM
600 RPM 900 RPM
Large Chilled Water System Design Seminar
Primary-Secondary-Tertiary Pumping Systems
Primary-Secondary-Tertiary
Zone C

Zone A

Zone B

C C
H H
I I
L L
L L Variable Speed Pump
E E
R R
 Three Different Buildings
• “A” has coils selected for 44°F.
• “B” has coils selected for 45°F.
• “C” has coils selected for 46°F.

• Therefore, the supply water temperature

must be at least 44°F for “A”.

• But what about “B” and “C”?

Primary-Secondary-Tertiary
can be very useful
Zone C

Zone A

Zone B

C C
H
I
H
I
?
L L
L L Optional Variable
E E Speed Pump
R R
Temperature Sensor Locations
MV
Load

MV
Load

Load MV
T1 T4 T1 T2 T3 T4

Tertiary
Zone
Pump Common T2
T3
Pumped ½” Circuit Setter
Chilled
Water
Supply

Chilled
Water
Return
 Tertiary Bridge
MV
Load

MV
Load

Load MV
T1 T4

Tertiary
Zone Common
Pump T2
T3
Pumped
Chilled
Water
Supply
Tertiary Bridge

Chilled
Water
Return
Temperature Sensor Locations
MV
Load

MV
Load

Load MV
T1 T4 T1
T2 T3 T4

Tertiary
Zone
Pump Common T2
T3
Pumped
Chilled
Water
Supply

Chilled
Water
Return
 ADVANTAGES
1. Permits operating at highest allowable zone temperature
2. Maximizes coil flow rate, good film coefficients
3. Maximizes flow rate through each control valve
4. Ensures good humidity control
5. Minimizes the amount of coil reheat
 DISADVANTAGES
1. Temperature of return water is unknown
2. Temperature of return water to chiller may be too high
3. Will not recognize increased supply water temperature
No single sensor location
satisfies all design criteria
SO........
Applying Zone Valve Controller
MV
Load

MV
Load

MV T1 T2 T3
Load
T1

Tertiary
Zone
Pump Common T2
T3
Pumped
Chilled
Water
Supply

Chilled
Water
Return
 Control Algorithm
1. Temperature control to the zone (T1 sensing).
2. If T1 is satisfied, return water temperature to the chiller
plant (T2 sensing).
3. Monitor secondary chilled water supply temperature
(T3 sensing) for temperature increase due to secondary
return water recirculation or temperature decrease due to
chiller leaving water temperature reset.
4. Reference point for automatic reset and T (T2 - T3)
control (T3 sensing).
 So what…?

• Satisfy zone cooling requirement at the

maximum possible supply temperature

• Minimize secondary flow rate

• Optimize return water temperature

 Multi-zone Application
Zone 1 Zone 2 Zone 3 Zone 4

Terminal Terminal
Unit Control Zone
Unit Balance (Tertiary)
Valve Valve Pump

Zone Supply
Temperature
T1 T1 T1 T1

Chiller Supply Common Common Common

Temperature T3 GPX T3 T3 T3
Return
Flow Water
Meter ]e
Temperature

3D Valves
T2 T2 T2 T2
C C C Distribution
h C
h h (Secondary)
i i o
i Pumps
l l l m
l l l m
e e e o
r r r n

Rolairtrol
 District Cooling Application
• Individual building temperature control
• Static pressure isolation
• Return water temperature control
• Btu/hr totalization
• Independent operation
 District Cooling Application
with GPX

• Independent pressure control

• HVAC fluid isolation

 VPF Application
Zone 1 Zone 2 Zone 3 Zone 4

Terminal
Unit Control Terminal Zone
Valve Unit Balance (Tertiary)
Valve Pump
Zone Supply
Temperature

T1 T1 T1 T1

Chiller Supply Common Common Common

Temperature T3 GPX T3 T3 T3
Return
Flow Zone Water
Meter Balance
Valve
Temperature

3D Valves
T2 T2 T2 T2
C C C B
h h h y
i i i p
l l l a
l l l
e e
s
e
r r r s

Rolairtrol
 Variable Flow
Through
The Evaporator
Variable Primary Flow
Two-position Control Valves Flow Meter, option

C C C

DP Sensor
H H H
DP Sensor

DP Sensor
DP Sensor

I I I
L L L
L L L
E E E
R R R

Modulating
Valve

AFD AFD AFD Controller

What’s different?

• Primary pumps only

• Flow meters or p sensors at each
chiller to monitor flow.
• Two-position isolation valves at each
chiller
• Minimum flow bypass with a modulating
control valve.
• “Smarter” controller.
Alternative #1

• Minimum Flow Bypass at Chillers

–Minimum Chiller Flow

–Minimum Pump flow

• Headered Pumps
 FLOW SUPPLY
T METER

F F F
SIGNAL
TO TECH

DP DP
SENSOR SENSOR
DP DP DP
CHILLER CHILLER CHILLER
SENSOR SENSOR SENSOR

SIGNAL SIGNAL BYPASS:

TO TECH TO TECH FOR SYSTEMS WITH
EXTENDED LIGHT
LOADS/WEEKEND
SIGNALS SIGNALS SHUTDOWNS. SET
TO TECH TO TECH BALANCE VALVE
FOR LOW FLOW TO
SIGNALS REDUCE THERMAL
TO TECH STRATIFICATION
AND ALLOW QUICK
START UP AFTER
SHUT DOWN.

TDV TDV TDV

T
NOTE:
ALL SENSOR RETURN
SIGNALS WIRED TO
TECHNOLOGIC
5500 AFD AFD AFD

ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
Controller
• Initial programming is
crucial.
• Must use accurate data
from the chiller
manufacturer.
• Start-up coordination
should include the BMS
too.
 Key Control Variables

1. Monitor zone differential pressure sensors,

compare actual values to the required set points.
• Pump speed is modulated to maintain set point.
• Pump staging will occur as required to meet set point.

Control sequence is exactly as described earlier.

 Key Control Variables
2. Determine if the minimum flow requirements are
being met for all working chillers.
Prevents freeze-up or chiller low-flow trips
If chiller flow is too low, controller opens minimum flow
bypass valve in programmed increments. Size the valve
for system p.
“Requests” de-staging action from the chiller control
system or BMS.
Allows for operator intervention, decision making.
Required by code in some areas.

Headered pumps allow operation of two chillers with

one pump.
 Key Control Variables
3. Monitors chiller flow rate to prevent operation
above the maximum flow for the chillers and the
pumps.
Excess chiller flow generates a request to stage on an
additional chiller. Minimum flow bypass valve is closed.
Operator or BMS intervention required.
Headered pumps allow operation of one chiller, two
pumps.
Optional system flow meter provides end-of-curve
protection for the pumps
Alternative #2

• Bypass at End of System

• Minimum chiller flow
• Minimum pump flow
• Headered Pumps
 FLOW
T SUPPLY
METER

F F F
SIGNAL
TO TECH

DP DP DP
CHILLER CHILLER CHILLER DP DP
SENSOR SENSOR SENSOR
SENSOR SENSOR

SIGNAL SIGNAL
SIGNALS SIGNALS TO TECH TO TECH
TO TECH TO TECH
SIGNALS
TO TECH

TDV TDV TDV

T
NOTE:
ALL SENSOR RETURN
SIGNALS WIRED TO
TECHNOLOGIC
5500 AFD AFD AFD

ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
Alternative #2
• Minimum flow bypass valve is controlled
to protect both the pumps and the
chillers.
– Pump requires >25% BEP flow
– Minimum flow of largest chiller
• Size the bypass valve using the zone
p.
• Best for systems with extended light
loads or weekend shut-down.
Alternative #3

• Primary pumps piped directly to chillers.

• More common in retrofit systems.
• Easier for applying un-equally sized
chillers in parallel.
 FLOW
SUPPLY
T METER

F F F
SIGNAL
TO TECH

DP DP
SENSOR SENSOR
DP DP DP
CHILLER CHILLER CHILLER
SENSOR SENSOR SENSOR

SIGNAL SIGNAL
BYPASS:
TO TECH TO TECH
FOR SYSTEMS WITH
EXTENDED LIGHT
LOADS/WEEKEND
SHUTDOWNS. SET
SIGNALS SIGNALS SIGNALS BALANCE VALVE
TO TECH TO TECH TO TECH FOR LOW FLOW TO
REDUCE THERMAL
STRATIFICATION
AND ALLOW QUICK
START UP AFTER
SHUT DOWN.
TDV TDV TDV

T
NOTE:
ALL SENSOR RETURN
SIGNALS WIRED TO
TECHNOLOGIC
5500 AFD AFD AFD

ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
 Consider this design if:
• System flow can be reduced by 30%.

• System can tolerate modest changes in water

temperature.

• Operators are well trained.

• Demonstrates a greater cost savings.

• High proportion of operating hours at:

– Part load.

– Full load with low entering condenser water.

 Turn-down Ratio
• Chiller manufacturers publish 3 - 11 fps
evaporator velocity range (typically).
• Nominal base of 7 fps desirable.
• You may have to increase your
“acceptable head loss” targets, use more
pump head.
• Variation of 1 to 2 fps.
• Work with the chiller manufacturer.
Operator Ability
• Within operator’s ability?.
– Commercial buildings may not have well
qualified operators.
• Training is mandatory.
– Initial
– Periodic, in view of operator turnover.
 Sensor Calibration
• Multiple sensors control:
– Flow
– Temperature
– Delta P
• Maintenance
• Calibration
• Location
Large Chilled Water System Design Seminar
Variable Speed Sensor Location
 What if?
Zone A Zone B Zone C
P Sensor here
Supply

C C C
H H H
I I I
L L L
L L L
E E E
R R R
Pump
AFDs Controller
Return
Sensor Across Mains At Pump
• What’s the set point?
– It’s the greatest branch and distribution
piping head loss calculated at design
flow. In other words…design head.
Differential Pressure Sensor
at the Pump
90

80
Design Point
70

60
Head, FT

50

40 Maximum rpm

30

20
Minimum rpm
10

0
0 200 400 600 800 1000 1200 1400 1600
Flow, gpm
Maximizing Variable Head Loss
Constant Head Loss

Supply
Differential
Pressure
Pump Sensor
Chiller 3

Chiller 2

Chiller 1

Controller

AFDs

Return

Variable Head Loss

 Control Area
Zone 1 Zone 2
20 ft 20 ft

A B C D

DP Sensor
C C C
H H H
I I I
L L L
L L L
E E E
R R R
Pump
AFDs Controller

E
F
 Pressure Drops in Piping

 P AB+EF  P Zone 1  P BC+DE  P Zone 2

20FT 20FT 20FT 20FT

TDH =  P AB + EF + BC + DE +  P ZONE 2 = 60 FT
 Control Area Calculation
Table 11-2 Control Area Calculation
Flow Flow Friction Friction P Friction Friction P TDH
Zone 1 Zone 2 Loss Loss Zone 1 Loss Loss Zone 2
AB+EF Zone 1 BC+DE Zone 2
0 gpm 600 gpm 5 0 40 20 20 20 45
300 gpm 300 gpm 5 5 25 5 20 20 30
600 gpm 0 gpm 5 20 20 0 0 20 25
0 gpm 0 gpm 0 0 20 0 0 20 20
600 gpm 600 gpm 20 20 40 20 20 20 60
What pump head is required at:
zero flow?
full flow?
less than full flow?
 Control Area
60

50

40
Head, FT

30

20
Lower Limit
10 Upper Limit
Single Point
0
0 100 300 500 600 900 1100 1200
Flow, gpm
 Single Sensor, Including
Balance Valve Pressure Drop
Zone 1 Zone 2
25 ft 20 ft

B (50) C
A

E (10) D
F
 What do you mean...?

• The head loss across the coil and the

wide open valve in zone 1 is 25 feet at
full flow.
• If that’s true, then we need to add an
extra 15 feet of head loss in the balance
valve to insure adequate flow out to
Zone 2 when the Zone 1 valve is wide
open.
 Set Point, Zone 1, 40 ft

Flow Zone 1 Flow Zone 2 Friction Loss Friction Loss Head Required Setpoint -
AB+EF BC+DE Zone 2 Friction Loss
0 gpm 600 gpm 5 20 20 0
300 gpm 300 gpm 5 5 5 30
600 gpm 0 gpm 5 0 0 40

Excess head means wasted energy

 Sensor Location
Zone 1 Zone 2

A B C D

DP Sensor
C C C
H H H
I I I
L L L
L L L
E E E
R R R
Pump
AFDs Controller

E
F
 Single Sensor in Zone 2
Zone 1 requires 600 gpm at 25 ft
Zone 2 requires 600 gpm at 20 ft

P Avail -
Flow Flow Friction Loss Friction Loss Friction Loss P Zone1, Friction Loss
Zone 1 Zone 2 AB+EF Zone 1 BC+DE Available Zone 1
0 gpm 600 gpm 5 0 20 40 40
300 gpm 300 gpm 5 6.25 5 25 13.75
600 gpm 0 gpm 5 25 0 20 -5

Inadequate head for Zone 1

 Sensor in Zone 1
Zone 1 requires 600 gpm at 25 ft
Zone 2 requires 600 gpm at 20 ft

Flow Zone 1 Flow Zone 2 Friction Loss Friction Loss Head Required Setpoint -
AB+EF BC+DE Zone 2 Friction Loss
0 gpm 600 gpm 5 20 20 5
300 gpm 300 gpm 5 5 5 20
600 gpm 0 gpm 5 0 0 25

Inadequate flow in Zone 2

 What can we do...?
In this system:
• Single sensor in Zone 2 at 20 ft fails to
provide adequate flow only when
– load in Zone 2 < 50% and
– load in Zone 1 > 75%
• Is this a predictable, recurring situation?
– manual adjustment
– programming
• Add a second sensor
 Applying Multiple Sensors
Zone A Zone B Zone C

Supply

DP Sensors
C C C
H H H
I I I
L L L
L L L
E E E
R R R
Pump
AFDs Controller
Return
Use Multiple Sensors?
• Load
– Similarity
– Priority
– Diversity
• One building or several
• Redundancy
• First cost vs operating cost
 Sensorless Control
60

50
Sensorless
40 Control Curve
Head, FT

30

20
Lower Limit
10 Upper Limit
Single Point
0
0 100 300 500 600 900 1100 1200
Flow, gpm
 Reverse Return Piped System

Supply

C
H
I
L
L
E
R

Return
 Summary
• Give priority to the needs of the branch.
• The rule of sensor location is simple and easy
to apply:
– If you have to use a single sensor, put it across
the critical branch.
– What’s the “critical branch”?
– It’s the same one that determined the pump head.
• As we’ve seen, the analysis is more important
than the “rule”.
 Questions?
Variable Speed Pumping for
Large Chilled Water Plants

Presented by:
Larry Konopacz, Manager of Training & Education
Bell & Gossett Little Red Schoolhouse

Thursday, October 22, 2015