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Optimization in HVAC Pumping Systems

Hvac

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Cristian Yanez
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100% found this document useful (1 vote)
214 views58 pages

Optimization in HVAC Pumping Systems

Hvac

Uploaded by

Cristian Yanez
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 58

Optimization in Water Pumping Systems

Insert Company Logo Here

www.armstrongfluidtechnology.com
2014 Armstrong Fluid Technology Slide 1 of 60
Optimization in Water Pumping Systems

SA Armstrong Limited
23 Bertrand Avenue
Toronto, ON M1L 2P3

Course Number: 0090011102


Learning Units: 1.0 LU/HSW Hour

S.A. Armstrong Limited, also known as Armstrong Fluid Technology, is a Registered Education Provider with the GBCI. Credit(s) earned on
completion of this program will be reported to the GBCI as part of the LEED Credential Maintenance Program. Certificates of Completion for all
audience members are available upon request.

This program is registered with GBCI for continuing professional education. As such, it does not include content that may be deemed or
construed to be an approval or endorsement by the GBCI of any material of construction or any method or manner of handling, using, distributing,
or dealing in any material or product.

Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without
written permission of the speaker is prohibited.

2014Armstrong Fluid Technology


2014 Slide 2 of 60
Learning Objectives

At the end of this program, participants will be able to:

differentiate traditional pump selection versus modern pump


selection to meet ASHRAE 90.1 requirements

discuss added values that provide cost and energy savings in


pumping units with integrated controls

describe how sensorless pump control works and its


advantages, and

list the various ways that integrated pumping systems can


contribute towards LEED points earned for a building project.

2014 Slide 3 of 60
U.S. Energy Consumption 2010
Total U.S. Energy
Buildings consume 40% of total
U.S. energy.
Industry Transportation
32% 28%
Of this 40%, HVAC systems
represent 17% of energy
consumption. Buildings
40%

Pumps play a pivotal role in HVAC U.S. Buildings


,0
Energy

systems.
Non-
Identifiable
10%
HVAC 17%

Other
Identifiable
13%

2014 Slide 4 of 60
Building Loads

Commercial buildings use chilled water systems for cooling,


and hot water systems for heating.

These systems operate at part-load the vast majority of the


time.

The emphasis on meeting heating and cooling loads tends to


encourage the practice of oversizing pumps.

A systems approach will typically yield a quieter, more


efficient, and more reliable hydronic system.

2014 Slide 5 of 60
ASHRAE Standard 90.1-2010 / 13

Section 6.5.4 of the ASHRAE 90.1


standard states:

6.5.4.1/2 Hydronic Variable Flow


Systems Individual chilled water
pumps serving variable flow systems
having motors exceeding 5 hp (3.7 kW)
shall have controls and/or devices (such
as variable speed control) that will result
in pump motor demand of no more than
30% of design wattage at 50% of design
water flow

2014 Slide 6 of 60
Building Load Profile

Most systems operate at less than 60% capacity, 90% of the


time or more.

2014 Slide 8 of 60
Variable Flow Pumping Systems

Can adapt to changing capacity


demands.

Should be designed for best


efficiency at part-load:
lower energy consumption
reduced operating costs, and
improved equipment reliability.

2014 Slide 9 of 60
Traditional Flow Control

Most of the buildings in the 1970s used


two basic types of flow control:
flow bypasses, or
throttling discharge valves with
trimmed pump impellers.

Bypass arrangements is the least


efficient and least used method of flow
control.

Throttling control does save energy


compared to bypass methods; a
variable speed operation can save
much more energy.
2014 Slide 10 of 60
Modern Control with Differential Pressure Sensor

The building industry has transitioned to using variable speed


pumps with two-way valves to achieve variable flow.

Today, a system composed of the pump, VFD, and sensor is


commonly used to control HVAC systems.

Differential
Pressure Sensor

Pump

Variable Frequency Drive

2014 Slide 11 of 60
Integrated Control Pumping Systems

These pumping systems with integrated controls can achieve the


lowest first cost AND lowest operating cost when the pump,
motor, and variable speed controls are integrated.

Control Options: Feature Options:


Pump manufacturer controls Integrated controls from 20 W to
Building management system 450 hp/315 kW
(BMS) Stand-alone controls to 1250
Sensorless mode hp/900 kW
Remote sensors Outdoor capable to 125 hp/90 kW

2014 Slide 12 of 60
Life Cycle Cost of Pumping System

Greatest cost in the lifetime of a


pumping unit is the operational
energy costs.

Operation energy factors include:


Optimized Capacity and Motor
Power
Pump Motor Starting
Quadratic Pressure Control
All-Variable Plant Controls, and
Sensorless Controls.

2014 Slide 13 of 60
Selections Save Energy and Cost

The average load efficiency is higher with an integrated control


pump when compared to a pump with wall-mounted controls
(non-integrated), and it is capable of saving 7% in pump costs
and 14% in energy costs.

4" Pump with non-integrated controls 3" Pump with integrated controls

Design Point: 72% efficiency Design Point: 68% efficiency


Average Load: 68% efficiency Average Load: 74% efficiency

2014 Slide 14 of 60
Optimized Capacity and Motor Power

Comparison of a 1000 USgpm @ 90 ft Traditional Integrated


Pump with Control Pump
pump, 40 hp motor vs. a 30 hp traditional Wall-
motor: Mounted
Controls

Savings in smaller motor and controls


Motor/integrated controls = $1,070 or
18%
Power wiring = $50 40 hp 30 hp
Total harmonic distortion = 25% reduction
50% flow is 30% or 12hp
30 hp motor delivers 12hp - 1.5
percentage points more efficient than
40 hp

2014 Slide 15 of 60
Pump Motor Starting

Pump motor starting


must provide a gentle
ramp up or down in
speed.

Direct-on-line is the
oldest way to start a
pump.

The current required


to start can go as high
as 700%.

2014 Slide 16 of 60
Pump Motor Starting

Star/Delta:
a relay switches the configuration from Star to Delta when the
motor reaches close to maximum speed

Soft Start:
electric timers monitor/limit either the voltage or the current
many of these devices cannot be used for long periods of time

VFDs/Integrated Controls:
controls both the frequency and the voltage simultaneously
provides full control over the acceleration/deceleration ramps
the best method of starting or stopping a pump
2014 Slide 17 of 60
Energy Savings: Control Curve Strategies

Using a quadratic pressure control (QPC) control curve can yield


more than 25% energy savings at part-load over a proportional
pressure control (PPC) control curve at part-load.

25%+
Energy Savings
at 50% Design Flow

2014 Slide 19 of 60
Energy Savings: Chiller and Cooling Tower

Using an all-variable plant:


lowers the chillers condenser
pressure requirement
lowers the chillers energy
consumption
enables higher tower performance
enables better system efficiency
through improved balancing of air
and water flow ratios

Integrated control pumps can be used


with ultra-high-efficiency plant
controllers to provide energy savings.

2014 Slide 20 of 60
ASHRAE 90.1-2010: Table 6.5.4.5

2014 Slide 21 of 60
Pumping Implications

For example, at 1400 USgpm, the ASHRAE


90.1-2007 requirement was 8" pipe.

Under 90.1-2010, the requirement is 10" for


variable speed systems, and 12" for
constant speed systems.

This provides another example of cost


savings from variable speed, integrated
control pumps:
10" pipe x 100 ft. long = $4,640 pipe cost
12" pipe x 100 ft. long = $5,260 pipe cost

2014 Slide 22 of 60
Sensorless Control

Pre-programs the pump


curve parameters into the
integrated controls.

Key Parameters
Flow
Head
Power
Speed

2014 Slide 23 of 60
Sensorless Control: Traditional Control with
Differential Pressure Sensor
In this simplified example, the chiller and pump are found in the
basement mechanical room, and the pump distributes chilled
water to the cooling coils.

2014 Slide 24 of 60
Sensor Location

One method is to install the


sensor at the most remote
load (1).

Another option is to install it in


the mechanical room (2).

Possible sensor locations:


1. Most remote load
2. Mechanical room

2014 Slide 25 of 60
Sensor Location in Mechanical Room

Minimum head is the same as the design head


Doesnt result in much energy savings at 50% load flow
Configuration wont meet the ASHRAE 90.1 energy standard
Very simple to install

A Design Point

B Minimum Head

2014 Slide 26 of 60
Sensor Location Remote Load

Configuration provides tremendous energy savings, meeting


ASHRAE 90.1 standard for energy efficient operation
Difficult to install

A Design Point

B Minimum Head

2014 Slide 27 of 60
Sensor Location Operating Cost Comparison

Sensorless control can provide the same performance as a


remote load sensor (Row E).
Incremental Cumulative
Pow
Pump Energy Energy
er
Savings Savings

Constant Speed Throttled


A Described in slide 15 32.03
Traditional method

Reduced Speed Unthrottled


B 27.11 15% 15%
Constant Flow

Reduced Constant Speed


C 19.36 29% 40%
Variable Flow
Points A and B are at the design flow.
Variable Speed
D Variable Flow 14.35 26% 55%
Points C, D, and E are 50% of design
Mechanical Room Sensor flow. Note that only E is able to meet
the ASHRAE 90.1 standard for 70%
Integrated Control Pump energy savings at 50% of design flow.
E Remote Load Sensor 7.32 49% 77%
Sensorless

2014 Slide 28 of 60
Installation Savings for Lowest First Cost:
Sensorless Controls
Sensorless controls provide
savings in multiple areas:
49% more energy saved
than with a sensor in the
mechanical room.

$2000 saved in
installation, wiring, and
sensor costs.

An estimated $600 per


pump comes from
simplified commissioning
alone.

2014 Slide 29 of 60
Sensorless Control On-Site

Installing an integrated pump system negates the 3-4 month wait


for commissioning of the sensors.

A 6x6x11.5 30 hp integrated pump system:


Cost of pump = $9,702 USD
Assume $0.10/kWh
Variable flow-constant speed operation = $10,312/yr
Variable flow-variable speed operation = $6,145/yr
Savings = $4,167/yr
Four-month savings = $1,389 or 14% of the pump cost

2014 Slide 30 of 60
Flow Meter and Control

Sensorless control can eliminate the need for a flow meter.


Sensorless mode provides the ability for digital flow readout
with an accuracy of +/- 5% and communication to the BMS.
Capabilities include minimum/maximum for pump flow output.

2014 Slide 31 of 60
Wiring VFD Mounting Bracket

With a sensorless control system,


the wiring and conduit running out
to the furthest pump can be
eliminated.

The only set of wiring comes


down from the ceiling.

The potential wiring variable


frequency drive (VFD) mounting
bracket savingsis estimated to
be $340 per pump.

2014 Slide 32 of 60
Harmonic Distortion

The integrated pump system controls have DC link reactors


built into the controls, equivalent to 5% AC line reactors.

DC link reactors help reduce power line transients and


mitigate harmonic distortion.
DC link reactors
built into integrated
pump system
controls

2014 Slide 33 of 60
Emission and Immunity

Integrated pumping systems


include radio frequency
interference (RFI) filters to
ensure compliance to low
emission and immunity
requirements.

Wall-mounted drives often do


not include these and must
provide them as an extra.

2014 Slide 34 of 60
Reflected Wave Voltage

If the distance between the


motor and the control is long,
a standing wave can form
between the motor and
control.
Bearing
Protection
Ring Kit
Locating the controls next to
the motor will mitigate this
problem and eliminate the
requirement for shaft
grounding (bearing protection
rings).

2014 Slide 35 of 60
Motor Accessories

Electric motors frequently


feature space heaters and
thermistors.

Integrated pump controls


eliminate the need for space
Space Heaters
heaters and thermistors. 30 hp 286T = $420

Thermistors
30 hp 286T = $420
Tripping relay = $550

2014 Slide 36 of 60
Re-Selection Risk and Cost

A pump with integrated controls will operate at high efficiency


levels and will provide the exact pumping performance that
supports the HVAC system and keeps costs at a minimum.

Occupant Load Changes Surrounding Shade Changes Building Design Changes

2014 Slide 37 of 60
Re-Selection Risk and Cost

Adaptability of an integrated
control pumping unit reduces risk
and cost.

Changes in design can cost $100


per hour for re-engineering.

Edmonton International Airport Edmonton International Airport


estimated a savings of $25,000 in A: Original design
B: Second design
re-selections during the C: Final design
construction phase alone.

2014 Slide 38 of 60
Energy Metering Capability

The integrated controls can be used:


as an energy meter for energy measurement verification, and
for trending analysis towards demand response.

2014 Slide 39 of 60
Wall Space

There is no room on this wall for multiple VFDs.

2014 Slide 40 of 60
First Cost

The cost to the Example: 1000 USgpm at 90 ft


Selection: 6x6x11.5 30 hp Integrated pump system

contractor for an Selections (energy and cost) $1,140

integrated pump Impeller Trim (energy and cost) ---

system: $9,900 Sensorless Control (eliminate DP sensor) $2,600

Smaller Size Motor and Control $1,070

Wiring VFD Mounting Bracket $340


Percentage of pump Harmonic Distortion
$440
cost found in savings: Emission and Immunity Requirements

up to 75% Reflected Wave Voltage $270

Motor Accessories $1,390

Envelope Re-selection Adaptability $300

Energy Metering Capability $100

Wall Space ---

TOTAL $7,650

2014 Slide 41 of 60
Vertical Inline over End Suction Configurations

The pump configuration can provide


tremendous savings and improve
the life cycle cost of the pump.

First cost savings


Pipe savings
Floor space savings
Maintenance savings

2014 Slide 42 of 60
End Suction Pump Installation

Additional costs come


from end suction pump
installation. 5

1. Coupling re-alignment 2

costs 3

2. Grouting costs
3. Inertia base costs 4

4. Concrete base costs


5. Flex connectors costs

2014 Slide 43 of 60
Integrated Pump over Horizontal Split Case

An integrated pump system eliminates the flex connectors, the


concrete bases, and inertia bases, and there is no realignment of
the flex coupling during commissioning.

3-Pump
3-Pump Integrated
Horizontal Split
Costs System Savings
Case System
6x6x11.5 30 hp
6x5x12
Installation $19,572 $8,327 $11,245 = 57%
$9,225
Floor Space 105.7 sq ft 44.2 sq ft
($150/sq ft)

2014 Slide 44 of 60
Integrated Pump over End Suction

A vertical inline dual pump is mounted directly into the piping,


inherently giving the smallest installed footprint.

2-Pump Integrated
2-Pump End Suction
Costs System Savings
System 6x5x10
8x8x10 20 hp
Installation $9,214 $3,444 $5,770 = 62%
$2,400
Floor Space 36.1 sq ft 20.1 sq ft
($150/sq ft)

2014 Slide 45 of 60
Pipe

The vertical inline pumps (VILs) present a huge opportunity for


pipe savings (4050%). Heres an example of a plant room
optimization for Glendale Arena, home of the Phoenix Coyotes.

2014 Slide 46 of 60
Floor Space

Bayfront Towers Tampa, FL Shorewood Packaging, Danville, VA


Shown here is a compact mechanical room with no This photo provides an example of how
space for two individual pumps and no space to mount mounting pumps off the ground can be a
drives on the wall. The solution is a simple, single, large solution to a lack of floor space.
air handling unit (AHU) system.

2014 Slide 47 of 60
Maintenance

Seal change-out is much faster on VILs compared to base-


mount: 30 minutes versus two hours.
Some VILs dont use bearings, which dramatically reduces
failures and maintenance costs.

2014 Slide 48 of 60
Benefits of Integrated Design vs. Traditional

This example illustrates the value that integrated control


solutions deliver.

Traditional Solution Integrated Control Solution Integrated Control Solution


Space: 100% Space: 44% Space: 26%
Installed Cost: 100% Installed Cost: 67% Installed Cost: 39%

2014 Slide 49 of 60
Benefits of Integrated Design vs. Traditional

A traditional solution in the pumping world is to add variable


speed drives together with a sensor to a bank of end suction
pumps mounted on huge inertia bases.

If we compare an integrated control solution to a traditional


end suction solution requiring 100% in space and installed
cost, we see that an integrated control solution provides
superior value.

With far less space requirements and fewer components,


space savings up to 26% is an obvious benefit. Space
savings translate to reduced installed cost up to 39%.

2014 Slide 50 of 60
Case Study: Expansion of Edmonton International
Airport Expansion
The design initially specified standard vertical inline pumps,
but the nature of the expansion provided an opportunity to
switch to 56 integrated control pumps.

The contractor found value in the elimination of wiring from


VFD to the motor, sensors and sensor wiring.

2014 Slide 51 of 60
Comparison: Savings from Integrated Control over
VFD

PAYBACK: 0 months
Not included: Smaller electrics commissioning savings

2014 Slide 52 of 60
Comparison: Savings from Integrated Control over
VFD

PAYBACK: 0 months
Not included: Smaller electrics commissioning savings

2014 Slide 53 of 60
Overview: LEED Certification

The U.S. Green Building Council (USGBC) is a 501(c)(3) non prot


organization composed of leaders from every sector of the building
industry working to promote buildings and communities that are
environmentally responsible, protable and healthy places to live
and work. USGBC developed the LEED (Leadership in Energy and
Environmental Design) green building certification program, the
nationally accepted benchmark for the design, construction, and
operation of high performance green buildings.

LEED credit requirements cover the performance of materials in


aggregate, not the performance of individual products or brands.
Therefore, products that meet the LEED performance criteria can
only contribute toward earning points needed for LEED certification;
they cannot earn points individually toward LEED certication.

For detailed information about the council, their principles


and programs, please visit www.usgbc.org.

2014 Slide 54 of 60
Integrated Pumping Systems: LEED Contribution

An integrated pumping system can make a valuable contribution


towards LEED accreditation.

Two prerequisites and three credits, representing 24 points in


the LEED for New Construction 2009 rating system

One prerequisite and up to 27 points, available through three


credits in LEED for Existing Buildings: Operations &
Maintenance.

Oversized pumps provide the opportunity for significant energy


efficiency improvement and a reduction in energy consumption.

2014 Slide 55 of 60
ASHRAE 90.1-2007

Pump Performance Specified for Appendix G Baseline Building

2014 Slide 56 of 60
LEED for New Construction & Major
Renovations
LEED NC and LEED Canada-NC 2009

EAp1: Fundamental Commissioning of Building Energy


Systems, Points Available: Required

EAp2: Minimum Energy Performance, Points Available:


Required

EAc1: Optimize Energy Performance, Points Available: 19

EAc3: Enhanced Commissioning, Points Available: 2

EAc5: Measurement and Verification, Points Available: 3

2014 Slide 57 of 60
LEED for Existing Buildings: Operations &
Maintenance
LEED EBOM 2009

EAp2: Minimum Energy Performance


Points Available: Required

EAc1: Optimize Energy Efficiency Performance


Points Available: 18

EAc2: Existing Building Commissioning


Points Available: 6

EAc3: Enhanced Commissioning


Points Available: 3

2014 Slide 58 of 60
ASHRAE 9.3.1 Construction Waste Management

Section 9.3.1 Construction Waste Management (mandatory)


9.3.1.2 Total Waste
9.3.4 Storage and Collection of Recyclables & Discarded Goods

Description:
A minimum of 50% of non-hazardous construction/demolition
waste material shall be diverted.
Total waste shall not exceed 42 yd3 or 12,000 lbs per 10,000 ft2
of new building area.
Relevant Benefits of an Integrated Pumping System:
Only one set of packaging on-site - on larger projects with 50
pumps, the impact can be significant.

2014 Slide 59 of 60
Thank you for your time

Questions?
This concludes the GBCI
Continuing Education Systems Course

www.armstrongfluidtechnology.com

2014 Armstrong Fluid Technology


2013 Slide 60 of 60

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