1. 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

2. 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

3. PUMP LIFE CYCLE COSTS

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

5. Evaluating Energy Efficiencies
Pump Selection 75’ TDH
Selection Results:

6. Evaluating Energy Efficiencies

7. Evaluating Energy Efficienies
Load Profile – 5 Duty Points

8. Evaluating Energy Efficiencies
2250 HR/Year

9. Evaluating Energy Efficiencies
Part Load Efficiencies

10. Evaluating Energy Efficienies
Duty Point Efficiencies

11. Evaluating Energy Efficiencies
Energy (kWh)

12. Increasing Pumping Efficiencies
Evaluate the Types of Pumps Installed

13. 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

14. 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

15. 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

16. 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

18. 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?

19. 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

20. 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

21. 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

22. Pump Sequencing, Traditional Way
Example:
Design: 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

23. Pump Sequencing, Efficiency based
Example:
Design: 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.

24. Pumps controlled based on a feedback Sensor……

25. 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.

26. 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.

27. 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

28. 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.

29. 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

30. 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?

31. 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

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

33. Packaged vs Site Built Cost Comparisons

34. $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

35. 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