GRUNDFOS WHITE PAPER

Pumping Control Methods and

Their Impact on System Efficiency

Reece Robinson
Technical Content Manager
Grundfos Building Services
 White Paper Pumping Control Methods and Their Impact on System Efficiency

When it comes to designing commercial The Importance of Pumps

HVAC and plumbing systems, engineers
Pumps are the heart of any commercial
have to overcome a number of challenges.
HVAC or pressure boosting system, so they
While everyone faces perennial budget
are the key to how the system performs.
and timeline issues, system efficiency is
Pump manufacturers strive to create
becoming a bigger concern every year.
pumps that offer the highest possible
In this white paper, we’ll discuss the
efficiencies, with mechanical enhancements
role of pumps in hydronic and pressure
and permanent magnet motors that
boosting applications, as we focus on the
deliver energy-saving variable speed pump
various pumping control methods and the
performance.
significant impact they have on overall
system performance and efficiency. In 2015, the Department of Energy (DOE)
upped the ante and mandated new pump
efficiency standards that will take effect in
Today’s Focus on Efficiency 2020. As a result of the new measure, the
In recent years, commercial building energy DOE projects that over the course of 30 years,
codes have gotten tighter in response to pumps meeting these standards will
environmental concerns and consumer reduce electricity consumption by about
preferences. The result of national efforts 30 billion kilowatt-hours — the equivalent
like the ASHRAE code requirements, of the annual electricity use of 2.8 million US
LEED certification, Energy Star and the households.²
Department of Energy’s Energy Efficiency As the intended outcome of the DOE
Programs is that over a span of nearly 40 mandate demonstrates, pump efficiency
years, buildings have become 50% more goes way beyond the pump itself and
efficient.¹ At the same time, designing extends to the vital role pumps play in the
systems to meet the new regulations has overall energy consumption of the buildings
become more of a challenge. In states like in which they operate. In other words, in
California, where Title 24 calls for even more both HVAC and plumbing applications, the
stringent efficiency requirements, this focus key to success is overall system efficiency.
is amplified. And that’s where pump control methods play
This means both engineers and contractors an important role.
have to understand all the tools at their
disposal for increasing system efficiency.

Complex systems may have multiple remote sensors and

control logic to adjust pump system set-point accordingly. 2
 White Paper Pumping Control Methods and Their Impact on System Efficiency

Variable Pressure Is Key In pressure boosting systems, this type of

to Efficiency control is used in municipal water supply
and service water boosting in commercial
In a nutshell, variable pressure control is a
buildings.
method used in variable speed pumping
that results in reduced pump energy costs. An illustration of why variable pressure
Variable pressure encompasses a number of control is preferred in these applications
control modes where pump head is reduced can be seen in Figure 1, which shows what
either linearly or quadratically as flow is happens when an uncontrolled (fixed speed)
reduced. centrifugal pump is used instead.

While the terms “proportional Pump Head vs. Required Head

pressure control” and even Curve shows how pump head rises as flow is
reduced, which leads to energy waste
“quadratic proportional pressure
control” are frequently used,
Energy is lost though PRV's, or control valves,
combining these words results in when pump head is the inverse of system need.

an oxymoron. Mathematically,
the term “proportional” H
Design Condition

describes a linear relationship,

while “quadratic” describes a
non-linear relationship. For
this reason, quadratic pressure Q
control should not be a subset Figure 1
of proportional control.
Notice that the pump head rises as flow
is reduced. This is quite often the exact
Applications opposite of what is needed to provide the
In HVAC systems, variable pressure control required flow. Variable pressure control
is most common in closed system (hydronic) eliminates this problem, delivering lower
applications configured as variable / primary pressure as flow reduces. This ultimately
or secondary pumping systems, where water results in greater efficiency and lower
is pumped to heating / cooling coils or air energy costs.
handling units (AHUs) with modulating
control valves.
3
 White Paper Pumping Control Methods and Their Impact on System Efficiency

or a combination of differential pressure and

power. Pump performance data is loaded
Changing Flow Demand into the pump control.
Variable pressure adapts to changes in flow
Power-based pump control, or controls
demand, delivering efficient performance
operating without sensors, have gained
even during partial-load scenarios, which
popularity over the last 10 years as well. Here,
occur much more often than full-load
pump performance curves are loaded into
situations. For example, a chilled water
the pump control and both pressure and flow
circulation system can have low flow
are estimated using the power consumed by
demands in the spring and fall months, and
the motor and drive. Caution must be taken
a service water booster system can have low
when using power-based control, as this
flow demands during off-peak hours.
method does not work on all pump types.
The pump head required during these low- Since the only thing being measured is motor
flow periods can be significantly lower input power (via the variable frequency
than what is required at peak (design) flow drive), there may be two points on the pump
periods due to the reduced friction losses curve that require the same power. An
in the pipes and fittings. Because of the example is shown below in Figure 2.
hydraulic relationship between pressure and
flow in piping systems, pump operation can
be controlled by only measuring pressure,
Power-based Control and Relation
without the need to measure flow. to Pump Performance Curve
Controlling pumps based on the pump’s power
consumption can intersect the pump curve at
Measuring Pressure multiple points, as demonstrated by points 1 and 2.

There are several options for measuring

H H
pressure, including type of equipment, and
where it’s located.

Because they are less intrusive and

inexpensive, pressure sensors have become kW
1 2
kW 1 2

more popular than flow sensors. Pump

Q Q
systems with pressure sensors (differential kW 1 = kW 2, Q = ?

pressure or individual suction and discharge Figure 2

pressure sensors) will calculate flow based
on the differential pressure across the pump,
4
 White Paper Pumping Control Methods and Their Impact on System Efficiency

Regardless, the use of both pressure sensors and constant pressure using a remote sensor. Figure 3
power-based control results in some form of below shows the control curves for each of these
variable pressure control. pressure control types in blue.

Common misconception: “If a 1. Constant pressure mode

pump-mounted sensor is used, the Constant pressure is technically not considered
pump can only operate in constant variable pressure control, but is a standard
pressure mode.” This is incorrect, as control mode for variable speed pumps. It is
current pump technology allows very widely used in service water boosting and
proportional and / or quadratic is occasionally required for hydronic circulation
pressure control even in systems systems, especially in those with higher-than-
with pump mounted sensors. normal pressures in low-flow conditions.

There are four main types of pressure control 2. Proportional pressure mode
for centrifugal pumps: constant pressure, In this mode, the pump head is reduced linearly
proportional pressure, quadratic pressure, and with flow.

Power-based Control and Relation

H to Pump
H Performance Curve
H H

The blue line denotes the control curve for each of the four main types of pressure control for centrifugal pumps.

1. Constant Pressure 1. Constant Pressure

2. Proportional Pressure 1. Constant
3. Quadratic
Q Pressure
Pressure Q 2. Proportional
4. Constant Pressure
2. Proportional
Pressure – Q Press
Remote Sensor

H H HH H H H

Constant Pressure1. Constant

Q Pressure Q 2. Proportional
2. Proportional Pressure Q
3. Quadratic
Pressure
Pressure QQ Pressure
3. Quadratic Q 4. Constant Pressure Q Pressure –
4. –Constant
Remote Sensor Remote Sensor
Figure 3

H H H
5
 White Paper Pumping Control Methods and Their Impact on System Efficiency

3. Quadratic pressure mode

Quadratic (or squared) pressure best The first three control modes —
simulates the characteristics of a system constant pressure, proportional
resistance curve, because friction losses have pressure and quadratic pressure
a quadratic relationship with flow. — can be what are called “pre-
programmed” control modes
4. Constant pressure remote mode and can be used with pump- or
This control mode uses a system-mounted system–mounted sensors and /
sensor that is strategically placed in the or power-based pump control.
piping system. Notice on the graphs in Figure
3 on page 5 that the resulting control curve
can essentially be the same for both quadratic
control and constant pressure remote.

Sensor Placement in Secondary Chilled Water Pumps

Coil A Coil B Coil C

SUPPLY

dP
Control

RETURN

Figure 4 6
 White Paper Pumping Control Methods and Their Impact on System Efficiency

Some basic examples of pump and piping Pump-mounted vs.

configurations with sensor placement are Remote Sensor
shown in Figures 4 and 5. Obviously, options
As previously mentioned, there are two
for placement will vary significantly based
ways to use sensors: either mounted on the
on project requirements.
pump or attached remotely. Following is a
brief overview of how each configuration is
used in both hydronic and pressure boosting
applications.

Sensor Placement in Service Water Booster System

Possible sensor placement in a service water booster system

Remote
Mounted Sensor

Diaphragm Tank

Discharge Piping
Package
Mounted Sensor
Water Supply Fixtures

Control

Suction Piping – City or Utility Water Connection

Figure 5

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 White Paper Pumping Control Methods and Their Impact on System Efficiency

Pump-mounted Sensor
When pump-mounted sensors or power- Variable Pressure Control With
based control are used (Figure 6, page 8), Pump-mounted Sensors
there must be two setpoints: head / pressure Maximum (design) flow is represented at
at design (or maximum) flow (A), and head / point A, while head / pressure at zero flow is
pressure at zero flow (B). These two settings shown at point B.

define the control curve characteristics.

To properly set these parameters during H
commissioning, the head at zero flow (i.e.,
fixed head) needs to be determined. This A
fixed head is also referred to as control head
B
Hydronic application: Hea d a t Setpoint
zero fl ow [ps i or ft]
For a hydronic circulation system, similar to (control head)
[ps i or ft]
the example illustrated in Figure 4 on page
6 , the fixed head would also represent the Q

control head required if a remote mounted Figure 6

differential pressure sensor were used.

Constant Pressure Control

Example: with Remote Sensor
Mode: Quadratic pressure control
Total head: 60 feet (26 psi) H
Fixed head: 30 feet (13 psi)
Therefore, the head at zero flow would
be programmed to 13 psi, and the total
Fri cti on
head would be programmed to 26 psi to Hea d
Setpoint =
represent the 50% reduction in head from Control Head
Control [ps i or ft]
design flow to zero flow. Hea d

Figure 7

8
 White Paper Pumping Control Methods and Their Impact on System Efficiency

Pressure boosting application: Remote Sensor

Like the example illustrated in Figure 5 on The last of the four pressure-based control
page 7 , the head at zero flow will be the modes involves the use of a remote sensor
elevation head (i.e., static head), plus the (Figure 7, page 8 ). When using remote
residual pressure required at the fixture sensors, only a remote system set-point is
furthest from the pump system. An example required for the pump system controller.3
of this might be a 10-story building with a
Hydronic application:
setpoint pressure of 85 psi at maximum flow
with an inlet pressure of 30 psi. This equates In a hydronic circulation system, a differential
to a boost pressure of 55 psi or a total head of pressure sensor is typically installed at
127 feet. a strategic location in the piping. The
secondary chilled water system example
in Figure 4 on page 6 shows a differential
Example: pressure (dP) sensor that measures the
Mode: Quadratic pressure control pressure loss through the coil, control valve
Total head: 127 (55 psi) and balancing valve.
Fixed head: 115 (50 psi)
The design philosophy is that if the total
Therefore, the head at zero flow might
pressure drop of these components is
be 80 psi with 50 psi being the static
maintained at a fixed value, sufficient flow
head and 30 psi representing the residual
will be provided to all the other coils in the
pressure. The remaining five psi would be
system. This sensor location is typically
the only variable component of the pump
selected based on a worst-case pressure loss,
head coming in the way of friction.
involving long runs of the main distribution
piping along with the pressure drops through
the coil and valves. This sensor location is
The frictional component of pump head in
often at the end of a circulation loop but
booster systems for multi-story buildings is
can also be 2/3 to 3/4 of the distance from the
typically less than 10% of the total head. The
pumps to the furthest coil.
percentage of head reduction in hydronic
circulation systems will be much greater
than those in pressure boosting systems.

9
 White Paper Pumping Control Methods and Their Impact on System Efficiency

Pressure boosting application: That would establish a predefined control

curve resulting in pump head approaching
Instead of maintaining a constant pressure
60 feet at peak flow rates.
at the pump system discharge piping, a
sensor is mounted at a location close to what But what if the actual total friction loss in
is called the “critical fixture.” The critical the system “as built” turned out to be only
fixture might be located on the top floor of a 10 psi instead of the calculated 13 psi?
multi-story building or at the furthest home Because the only fixed head is the remote
from the pump system for municipal water sensor setpoint of 13 psi, the total pump
supply. head as flow approaches design conditions
only goes to 23 psi (10 psi + 13 psi) or 53 feet
of head. In this way, energy is saved because
Which is better: pump-mounted or in the reality of actual operating conditions,
remote-mounted sensors? 60 feet of head is not necessary. The result of
The answer depends on your specific this new lower total head is shown in Figure
application. However, there is one distinct 8. Note that the remote setpoint (control
advantage of remote sensors. If the frictional head) remains unchanged yet the total pump
(variable) component of the total pump head head is reduced resulting in lower pump
is less than what was calculated, pumps with speed and energy.
remote-mounted sensors can potentially
operate more efficiently than systems with
pump-mounted sensors. Let’s go back to
Impact of Pump Performance
one of our previous examples of a hydronic with Reduced Friction
circulation system to show why. Actual friction head
lower than calculated:
H Setpoint remains unchanged
but total pump head is reduced,
Example: resulting in lower pump energy

Mode: Quadratic pressure control

Ori gi nal
Total head: 60 feet (26 psi) Fri cti on
Hea d Setpoint =
Fixed head: 30 feet (13 psi) Control Head
Control [ps i or ft]
Therefore, the head at zero flow would Hea d
be programmed to 13 psi, and the total
head would be programmed to 26 psi to Q
Figure 8
represent the 50% reduction in head from
design flow to zero flow.
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 White Paper Pumping Control Methods and Their Impact on System Efficiency

Because total pump head is often over-

estimated, the use of remote sensors acts as Rated
Rated Pump
H, pump Curve
curve
a failsafe, effectively right-sizing the system Pump selected for a design capacity of 500 gpm
% Eff
at 60 feet of head
to ensure efficient pump operation despite 60

the differing pressures.

H,
Systems with pump-mounted sensor H,
% Eff
% Eff
controls can be adjusted to reflect the lower 60 500 Q
60
frictional losses, and achieve this same result.
However, these systems require additional BHP

monitoring and setpoint adjustments to

500 Q
determine the optimum setpoint. 500 Q Q

BHP
BHP
Impact of ASHRAE Energy
Standard 90.1 Q
Figure 9 Q
There is a direct connection between the
ASHRAE Energy Standard 90.1³ and the
control modes discussed here. The two
Rated Pump Curve with
sections that mention pumps are: Control Curves
Control, efficiency and power curves illustrated
6.5.4.2 – Hydronic Variable Flow Systems
Rated Curve
10.4.2 – Service Water Pressure-Booster Systems Constant Pressure
Rated Curv
Rated Curv
Constant P
H, Proportional Pressure Constant P
Proportion
The requirement for Hydronic Variable H,
% Eff Flow H,
% Eff
Quadratic Pressure Proportion
Quadratic
Quadratic
Systems states that the system must have % Eff
60 60
controls that will result in pump motor 60

demand to be no greater than 30% of design

wattage at 50% of the design water flow.
A proportional or quadratic pressure control 150 150 500 Q
150 500 Q 500 Q
mode is required to meet this requirement.
BHP
For pressure boosters, there is no energy
BHP BHP

reduction requirement, but the use of

150 500 Q
pressure regulator valves to control system 150 Figure 10 150 500 500 Q
Q

11
 White Paper Pumping Control Methods and Their Impact on System Efficiency

discharge pressure is not allowed. This The most significant reduction in pump
requires variable speed pump controls, and a power, as seen in Table 1, page 12, is
remote-mounted sensor — or software that accomplished by using a constant pressure
simulates remote sensing — must be used in control over a fixed speed (unregulated)
conjunction with variable speed controls. pump, for a 53.3% decrease in power.
When moving from constant pressure to
In both cases, quadratic pressure control or
proportional pressure, another big drop
remote sensing is the preferred method to
in power is achieved, reducing power by
meet the requirements of the code.
another 42%. Lastly, when moving from
proportional pressure control to quadratic
Difference in Energy Consumption control, an additional power reduction of
19.5% can be achieved.
Since energy savings are the primary driving
factor for the use of variable pressure When looking at just the three variable
control, let’s look at an example of the power speed-controlled pumps, the largest
reduction of a typical hydronic circulation reduction in power occurs when moving
pump using the different control modes. from constant pressure to proportional
Let’s examine the performance curve for a pressure. It may not always be possible to
pump selected for a design-day capacity of utilize quadratic control or even proportional
500 gpm at 60 feet of head (Figure 9, page pressure control, so it’s important to
11 ) and the impact different control modes understand that there still can be significant
have on efficiency and power (Figure 10, page energy savings when using constant pressure
11 ). Notice pump efficiency at low flow is control over fixed speed pumps. This is most
greatest when quadratic control is used (peak important when looking at replacing existing
efficiency shifts to the left). fixed speed pumps.

Performance Comparison at 150 gpm

Impact of control mode on pump with a performance at 150 gpm, or 30% of design flow.

Control Mode Speed [rpm] H [ft] Eff [%] bhp Savings

Unregulated 3500 108.3 48.1 8.53 –
Constant Pressure 2657 60 57.2 3.98 53.30%
Proportional Pressure 2165 39 63.9 2.31 42.00%
Quadratic Pressure 1994 32.7 66.5 1.86 19.50%

Table 1 12
 White Paper Pumping Control Methods and Their Impact on System Efficiency

Parallel Pump Control Conclusion

The use of parallel pumping can help to By now you’ve gathered that for most
achieve even greater efficiencies, as smaller systems, the quadratic control curve will
pumps can be used, and duty can be result in the greatest energy savings,
distributed in a much more efficient manner. provided the controls are programmed
When using parallel connected pumps, to match the system characteristics. But
especially with pump-mounted or power- it’s not always easy to achieve the desired
based sensing, make sure that the control results with field-built pump systems where
curve is set to incorporate all connected pumps, drives and controls come from
duty pumps as shown in Figure 11, page 13 . different manufacturers. Connecting two
Individual pumps often come with integrated or more pumps in parallel, which is often
controls that can be field-connected to work required, adds another level of difficulty, as
in parallel. This can result in pumps operating the controls need to be set up for redundancy
on single pump control curves that can and / or cascade operation.
produce more head than necessary and can
One way to eliminate many of these
consume more energy than is required.
challenges is by choosing a packaged
The use of packaged systems built to pumping system. Packaged systems can
incorporate parallel pumps helps reduce the come with sensors on the inlet and outlet
extra work of configuring individual pumps manifolds (or differential pressure sensors),
with individual controls into a multi-pump and can be programmed to provide either
parallel system. proportional or quadratic pressure control.
Any set-point changes can be made on a
Control Curve for Pumps single pump controller either at the control
panel or through the building management
Connected in Parallel system (BMS).
Incorporating all connected duty pumps
ensures efficient operation. When remote sensors are used, many
packaged systems can be programmed to
provide pressure control in the event of a
remote sensor failure.
H

P1 P1+P2

13
Q
Figure 11
 White Paper Pumping Control Methods and Their Impact on System Efficiency

When the remote sensor signal is lost, the packaged system can revert to the package-
mounted sensors while the remote sensor problem is being resolved. In some cases, the
remote sensor location can turn out to be suboptimal. While a new remote sensor location is
being tested, package-mounted sensors can provide the needed backup control.

Another benefit that comes with the packaged system is ease of integration to the BMS.
All information regarding pumps, drives, controls and sensors can be transmitted through a
single pump controller.

While energy efficiency continues to grow in importance, it seems project completion time and
budgets continue to shrink proportionally. Faced with these challenges, engineers must begin
to think about new ways to accomplish old tasks. The use of variable pressure control modes,
a sensor system that best fits your application, and the consideration of packaged pumping
systems can all be combined to achieve better results in less time, while saving money.

References
1. Halff. “Why Benchmarking Your Buildings for Energy Efficiency Is So Important,” 2018.

2. Mauer, Joanna. "First-ever pump efficiency standards reflect industry and advocate
consensus,” American Council for an Energy Efficient Economy, 2015.

3. ASHRAE (2016). ANSI/ASHRAE/IES Standard 90.1-2016: Energy Standard for Buildings

Except Low-Rise Residential Buildings (I-P Edition). Atlanta: ASHRAE.

4. ASHRAE (2016). 2016 ASHRAE Handbook—HVAC Systems and Equipment. Atlanta:

American Society of Heating.

14
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