Presented by Mike Zacharias Pumping Systems, Flow Control, and Technology - An Update on Physics, Reliability, and Energy Efficiency for the Modern Hydronic System Presented by Mike Zacharias Cougar USA April 1, 2019

Modern Pump Control Strategies Packaged vs Site Built systems Pumping Systems, Flow Control, and Technology An Update on Physics, Reliability, and Energy Efficiency for the Modern Hydronic System Pumping Efficiencies Modern Pump Control Strategies Packaged vs Site Built systems Welcome to todays presentation on Pumping Systems, flow control and Technology. Today you’ll simply receive an update on the physics, reliability and energy efficiency for the modern hydronic system. We’re going to look at three main topics: Packaged vs Site Built Systems Modern Pump Control Strategies And Breakthroughs in Pumping Efficiency

PUMP LIFE CYCLE COSTS

Evaluating Pump Efficiencies Design Loads vs Actual Loads Part Load Efficiencies Pump Designs Pump Controls

Evaluating Energy Efficiencies Pump Selection 1000 @ 75’ TDH Selection Results:

Evaluating Energy Efficiencies

Evaluating Energy Efficienies Load Profile – 5 Duty Points

Evaluating Energy Efficiencies 2250 HR/Year

Evaluating Energy Efficiencies Part Load Efficiencies

Evaluating Energy Efficienies Duty Point Efficiencies

Evaluating Energy Efficiencies Energy (kWh)

Increasing Pumping Efficiencies Evaluate the Types of Pumps Installed

Pump Types used in Hydronic Heating and Cooling Horizontal Split Case End Suction Frame Mounted The most common pump types in hydronic heating and cooling systems are shown here End Suction Frame Mounted, End Suction Close-Coupled, Single Stage Inline <click> Shown here to the right is a vertical multi-stage pump which is commonly used in higher head applications such as boosting and steam boiler feed. But this style of pump is gaining popularity, and with good reason, in lower head hydronic heating and cooling applications. <click to show shorter multi-stage> Although it’s a multi-stage pump, it can contain only one stage for lower head applications. Vertical Inline Multi-Stage End Suction Close Coupled Vertical Inline Single Stage

Increasing Pumping Efficiencies Question: Should Vertical Multistage Pumps be used in low head HVAC applications? Answer: YES Life cycle cost show value Efficiencies (up to 80%) Much Smaller Footprint Significantly Reduced Maintenance Costs

SINGLE VS. MULTI-STAGE Multi-Single Stage Curve Single Stage Curve At 25 gpm the VFD controlled Multi-Stage will consume 45% less energy (2.3 bhp vs. 4.2 bhp) than the fixed speed single stage pump Multi-Single Stage Curve Single Stage Curve Duty Point

Increasing Pumping Efficiencies Evaluate the Types of Pumps Installed Evaluate the Sizing & Number of Pumps Installed One Pump sized for 550 GPM Three Smaller Pumps each sized for 183 GPM

Increasing Pumping Efficiencies Evaluate the Types of Pumps Installed Evaluate the Sizing & Number of Pumps Installed Single Pump sized for 550 GPM Three Pumps each sized 183 GPM What About System Controls?

Advancement in Pump Controls Many Pump Manufacturers can offer the following with their packaged pump systems: Cascade Control Efficiency based sequencing Hour counter/equal run time Pump Protection Motor Overloading Bearing Monitoring Check valve failure detection Lost Sensor Reaction Revert to backup sensor Revert to programmed pump speed Change from remote sensor to header sensor Integration to BAS Stand Alone Control with BAS Integration – Read & Write All alarms, pump, drive, sensor info. available from a single point

Cascade Control - Pump Sequencing Traditional Ways: > Speed (RPM/Hz) > Flow (requires flow sensor) > Demand (set-point not being met) Most efficient way > Pump Efficiencies Run the number of pumps required to achieve the highest efficiency

Efficiency Based Pump Sequencing Pump Curves loaded into controller Flow and head at all speeds are known Controller will determine which combination of pumps are most efficient

Pump Sequencing, Traditional Way Example: Design: 1150 gpm/85 ft 2 Pumps can do the job (shaded area), both pumps at 98% speed and a pumping efficiency of 73% N + 1 Here’s an example of how efficiency based sequencing can help save energy. Shown here is a pump performance curve showing the total capacity for three parallel connected pumps. The darker area shows the range for the two duty pumps. So for a flow of 1150 gpm at a head of 85 feet, two pumps can handle the conditions with the third pump being the spare pump which is common practice for redundancy. The efficiency of the two pumps is 73.3%. 5

Pump Sequencing, Efficiency based Example: Design: 1150 gpm/85 ft 3 pumps in operation even though 2 can do the job. Pump efficiency has been increased from 73% to 77% N + 1 Here’s the same three pump system but with all three pumps running. Even though two pumps can handle the condition, the addition of the third pump has resulted in a pump efficiency of 77.1%. Because the pump controller is receiving pump inlet and outlet pressure and has the pump curve information loaded in, it can continuously determine pump efficiency and operate the system where its most efficient. This is what some call the N+1 strategy. If one of the three pumps goes down, the system can still meet the design conditions.

Pumps controlled based on a feedback Sensor……

Sensor Placement - Hydronic Circulation Differential Pressure measured remotely SUPPLY RETURN Coil A Coil B Coil C Coil D dP Shown here is a typical layout showing a primary/secondary pumping arrangement. Variable Frequency drives are used on the secondary set of pumps where variable flow conditions occur. It is common to place a differential pressure transmitter near the end of the loop, usually across the supply and return piping to the last coil <click> Placing the dP sensor as shown will ensure enough pressure is supplied to each coil upstream of that one which will result in sufficient flow to all circuit.

Sensor Placement - Hydronic Circulation Differential Pressure measured remotely SUPPLY RETURN Coil A Coil B Coil C Coil D dP dP sensors may also be placed at other strategic locations depending on how the piping and coil losses are distributed.

Sensor Placement - Hydronic Circulation Differential Pressure measured across pumps SUPPLY RETURN Coil A Coil B Coil C Coil D dP With modern pump controls, dP sensors can be supplied with the pump package and the system can be programmed to simulate the effect of a remote mounted sensor. Integrated control technologies can simulate the effect of a remote sensor using proportional pressure control which reduces pump head with reducing flow

Backup Sensor If remote dP signal is lost, controls can be set up to revert to header sensors to keep pumps running variable speed SUPPLY RETURN Coil A Coil B Coil C Coil D dP dP With modern pump controls, a backup sensor can be programmed in so that when the primary sensor signal is lost, the system can revert to a different sensor to maintain some type of control.

Increasing Pumping Efficiencies Evaluate the Types of Pumps Installed Evaluate the Sizing & Number of Pumps Installed Single Pump sized for 550 GPM Three Pumps each sized 183 GPM What About System Controls? Install Packaged Pumping Systems

Packaged Equipment is nothing new…. Chillers are always purchased with controls Boilers are always purchased with controls Why not look at pumps the same way? Packaged equipment is not new to the industry. Equipment such as chillers and boilers come packaged with sensors and controls. Would you purchase a chiller without controls? Would you purchase a boiler without controls? Why not look at pumps the same way?

Why package pump systems? Manufacturers Know Their Equipment Best Shop Fabrication vs Field Fabrication – Lower Costs/Higher Quality Smaller Footprint Single Point Responsibility System Specific Controls = More Efficient Operation Reduced Uncertainty = Reduced Risk Better Aftermarket sales support

Site Built vs Packaged First we’ll take a look at Site Built vs Packaged Systems

Packaged vs Site Built Cost Comparisons

$22,591 $18,599 Individual Pumps, for a 2-pump HW system: 2 Housekeeping Pads 2 Inertia Bases with grouting etc. 2 Suction diffusers, triple duty valves 2 Sets of expansion joints 2 Variable Speed Drives Multiple Line & Load Electrical Connections 2 Pump Alignments, adjustments etc. BAS Integration & Control Required Packaged System with 2 VMS pumps: 1 Housekeeping pad, NO grouting. NO suction diffusers or triple duty valves 1 set of expansion joints (optional) Single Point Electrical Connection No shaft/coupling alignments, adjustments etc. Integrated Controls BAS Interface $22,591 $18,599

Conclusions Part Load Efficiencies are Critical Take a “Modular” Approach to Pump Sizing & Selection Integrated Controls Maximize Efficiencies Consider Vertical Multistage Pumps Install Packaged Pumping Systems