More Related Content
What's hot
What's hot (20)
Viewers also liked
Viewers also liked (20)
Similar to Ashrae 90.1 and the future of pumping part 1
Similar to Ashrae 90.1 and the future of pumping part 1 (20)
Ashrae 90.1 and the future of pumping part 1
- 1. ASHRAE 90.1, Lowest Energy, First and Life Cost Future of Pumping Cover image should be high quality and cover this shaded area
- 2. Agenda • Review ASHRAE 90.1 – 2010 requirements relating to balancing & pumping • Review traditional pump selection against ASHRAE 90.1 • Introduce Design Envelope IVS concept for selections to meet ASHRAE 90.1 • Inherent added values in Design Envelope pumping units • Sensorless control • Energy savings in plumbing booster systems Where standard is referenced Black is the standard Red is the Armstrong solution Brazil Visit 2012
- 3. ASHRAE Standard 90.1 - 2010 • Energy Standard for Buildings • Purpose: To provide minimum requirements for energy-efficient design of buildings • Does not apply to single family dwellings; multi-family structures of 3- stories or less • Most North American Building Codes have adopted ASHRAE 90.1 standards Brazil Visit 2012
- 4. 6.7.2.3.3 System Balancing • All HVAC systems shall be balanced • Written balancing report provided to owner for conditioned areas exceeding 5,000ft² (500m²) • “Hydronic Systems shall be Proportionately Balanced in a manner to first minimize throttling losses” Brazil Visit 2012
- 5. 6.7.2.3.3 System Balancing “Then the pump impeller shall be trimmed or [max] speed adjusted to meet design flow conditions” Brazil Visit 2012
- 6. Balancing : Industrial Practices Manual balancing / conventional controls valves Advantage : - lower first cost - Ashrae 90.1 conformance Disadvantages - System must be properly balanced - Adjustment may be needed to ensure flow on legs closest to the pump 6 Brazil Visit 2012
- 7. Balancing : Industrial Practices Dynamic balancing : Flow limiter Advantages: -No balancing commissioning required Disadvantages: 1.Higher pump head required 2.Higher initial valve cost 3.No function at partial load 4.Does not meet ASHRAE 90.1 5.Tendency to clog 6.Confusing to install 7 Brazil Visit 2012
- 8. Balancing : Industrial Practices Dynamic : PIBCV : pressure independent balancing & control valve Advantages : - easy selection and commissioning - Flow required to space is maintained reducing hunting and energy Disadvantages - Must ensure valve is bought from a quality supplier and characteristics are as advertised - higher first cost - higher pump head can be required -ASHRAE 90.1 proportional balancing is not met 8 Brazil Visit 2012
- 9. Armstrong Solution : manual balancing + variable speed pumping 7℃ >12℃ Obtain designed comfort at min. energy consumption Chiller : operating at right flow and temp. Pumping : running at right flow BMS : modulating with proper valve authority Valves can be eliminated on constant flow circuits using Sensorless control. 37℃ 32℃ 12℃ 7℃ 9 Brazil Visit 2012
- 10. System Balancing If conventional control valves are used, Armstrong recommends • Control valves are properly selected • Manual balancing valves proportional balanced • Design Envelope IVS CHW/Heating variable flow pumps are controlled by either sensor in the system for parallel or sensor- less control for duty/standby • For constant flow circuit valves can be eliminated using sensorless control 10 Brazil Visit 2012
- 11. 6.7.2.3.3 System Balancing • “Then the pump impeller shall be trimmed or [max] speed adjusted to meet design flow conditions” • Armstrong – suggests all pumps should have integrated controls! • Eliminate throttling in constant flow applications • 15% energy reduction • Variable Flow • 75% energy savings available • Optimized impeller trim at factory level • Smaller electrics Brazil Visit 2012
- 12. Why have Throttling ability in Variable Flow System? Head/Press re Speed 1 • Ideal is Throttle AVAILABLE if system u is outside pump operation • Reducing speed will System not achieve this Speed 2 Resistance • Use on all pumps A D B A = Design Point C B = Actual Site Duty Point C = Reduced Speed without throttling D = Reduced Speed with Throttling Flow Brazil Visit 2012
- 13. Pumps - Lowest Installed Cost Flo-Trex Valve • Multi Function • Drip tight Shut off Valve • Non-Slam Check Valve • Flow Throttling Valve • Straight also Available • Sizes up to 350mm • Grooved ends Brazil Visit 2012
- 14. Suction Guide and Flotrex Savings Suction guides and Flotrex save components and 30 % in installed costs! • 1. “Y” Strainer • 2 . Suction long radius elbow • 3. Discharge long radius elbow • 4 . Discharge check valve • 5 . Discharge globe valve • 6 . Suction spool piece Brazil Visit 2012
- 15. 6.5.4 Hydronic System Design and Control • 6.5.4.1 Hydronic Variable Flow Systems • HVAC pumping systems having a total pump system power exceeding 10hp (7.5kW) that include control valves designed to modulate or step open and close as a function of load, shall be designed for variable fluid flow; and shall be capable of reducing pump flow rates to 50% or less of the design flow rate • 3 way valves not acceptable Brazil Visit 2012
- 16. 6.5.4 Hydronic System Design and Control • 6.5.4.1 Hydronic Variable Flow Systems • … Individual chilled water pumps serving variable flow systems having motors exceeding 5hp (3.7kW) 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 … • Armstrong – 2010 at 5hp (3.7kW) vs 2001 at 50hp (37kW) • All pumps 1hp (0.75kw) and over should have integrated controls Brazil Visit 2012
- 17. 6.5.4 Hydronic System Design and Control • 6.5.4.1 Hydronic Variable Flow Systems • … The controls or devices shall be controlled as a function of desired flow or to maintain a minimum required differential pressure. • Differential pressure shall be measured at or near the most remote heat exchanger or the heat exchanger requiring the greatest differential pressure. The differential set-point shall be no more than 110% of that required to achieve design flow through the heat exchanger. Brazil Visit 2012
- 18. Traditional constant speed pump selection Series 4300 8x8x10 •Selection to left of BEP 120 10.19 50 100 71 83 •1250gpm at 70ft 9.30 80 •79.1% eff Head (ft) 8.00 BEP 60 71 •27.9 bhp 40 40 hp •40 hp installed 30 hp 20 System curve 0 0 0.5 1 1.5 2 2.5 3 Flow (1,000 usgpm) Brazil Visit 2012
- 19. Variable Speed Operating Curve – 28ft min press Series 4300 8x8x10 @ 9.3 in 120 Minimum Pressure set 100 1848 50 40 hp at 40% design head 1760 rpm 68 75 80 80 82 Head (ft) 80 60 75 Operating curve 68 40 30 hp Feedback System curve sensor set-point 528 0 0.5 1 1.5 2 2.5 Flow (1,000 usgpm) Brazil Visit 2012
- 20. Traditional selection at 50% flow Series 4300 8x8x10 @ 9.3 in 120 •625gpm at 38.5ft 100 1848 rpm 50 68 40 hp •67.1%eff 75 80 80 82 •9.06bhp Head (ft) 80 60 75 Operating curve 1240 68 40 30 hp 1012 20 System curve System curve 528 0 0.5 1 1.5 2 2.5 Flow (1,000 usgpm) Brazil Visit 2012
- 21. Traditional Pump Selection Energy Savings Traditional selection Operating point at (left of BEP): 50% design flow: 67.5% 1250gpm at 70ft 625gpm at 38.5ft ENERGY SAVINGS 79.1% efficiency 67.1% efficiency Below ASHRAE 90.1 27.9 bhp 9.06 bhp requirements! Brazil Visit 2012
- 22. Design Envelope IVS Pump Selection Series 4300 Design Envelope 0611-040.0 Integrated Intelligent Variable Speed with Sensorles Control 160 63.0 Hz 57 •Selection to right of BEP 140 68 77 82 120 58.6 Hz 84 85 •1250gpm at 70ft 84 82 100 77 •68.1% efficiency Head (ft) 68 80 •32.5bhp 60 40 hp 40 Control curve BEP 27.9 Hz 20 System curve 18.0 Hz 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 Flow (1,000 usgpm) Brazil Visit 2012
- 23. Design Envelope IVS Selection at 50% Flow Series 4300 Design Envelope 0611-040.0 Integrated Intelligent Variable Speed with Sensorles Control 160 63.0 Hz 57 •625gpm at 38.5ft 140 68 77 82 120 84 85 •83.2% efficiency 84 82 100 77 •7.31bhp Head (ft) 68 80 60 40 hp 36.9 Hz 40 Control curve 20 20.7 Hz System curve System curve 18.0 Hz 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 Flow (1,000 usgpm) Brazil Visit 2012
- 24. Design Envelope IVS Pump Selection Energy Savings Design Envelope IVS Operating point at selection: 50% design flow: 77.5% 1250gpm at 70ft 625gpm at 38.5ft ENERGY SAVINGS 68.1% efficiency 83.2% efficiency Exceeds ASHRAE 90.1 32.5bhp 7.31bhp requirements! Brazil Visit 2012
- 25. Design Envelope IVS Selection Software Brazil Visit 2012
- 26. Cross-hairs Pin Envelopes for Design Conditions Brazil Visit 2012
- 27. Variable Speed Pump Selection – 1250gpm at 70ft •Lowest operating cost with eye on price •#1 rank must repay lower price difference within 3-years •0810-030.0 has $982 lower price than 0611-040.0 •Improved operating cost of 0611-040.0 pays off price difference in 22-months at $010/kWh Brazil Visit 2012
- 28. Design Envelope IVS Pumping Units • Lowest pump operating costs • True plug & play • Integrated controls to 350hp/250kW • Stand alone controls to 1250hp/900kW • Outdoor capable to 125hp/90kW • Pumps controlled by • Armstrong IPS controls • BMS system • Sensorless mode • Remote Sensors Brazil Visit 2012
- 29. Design Envelope IVS Pumping Suite 4300 4302 4380 4382 Indoors Integrated to 350hp to 100hp to 7.5hp to 7.5hp Standalone 400-1250hp Outdoors Integrated to 125hp to 100hp to 7.5hp to 7.5hp Brazil Visit 2012
- 30. Design Envelope IVS Advantages vs. Wall Mounted VFD VS. Brazil Visit 2012
- 31. Design Envelope IVS Advantages Selections Save Energy and Cost Wall-mounted Design Envelope IVS 4” pump 3” pump Traditional pump with design point to Design Envelope IVS pump with the left of BEP design point to the right of BEP Design point 72% 68% Average load 68% 74% Envelope selection often smaller and in a typical example saved 7% in pump cost and 9% in energy costs Brazil Visit 2012
- 32. Optimized capacity and motor power • Impeller trim is optimized to the motor power 53.5 lps @ 27 m 18.5 kW vs. 22 kW traditional • Electronic load limiting Savings in smaller motor & controls Motor/integrated controls = $460 or 9% Power wiring = $50 BEP Harmonics = 16.6% reduction A C 30 kW A B Design Envelope B 22 kW pump (18.5 kW) 15 kW 18.5 kW A C Traditional pump (22 kW) Brazil Visit 2012
- 33. Design Envelope IVS Advantages Sensorless Savings and Superior Control No pressure sensors • Saving 49% more necessary energy than a Design Envelope sensor in the IVS pumps mechanical room • Cost savings of $2000 in installation, wiring, and sensor costs • Simplified commissioning alone is estimated to save $600 per pump Mechanical room Brazil Visit 2012
- 34. Design Envelope IVS Advantages Flow Meter Savings and Superior Control • Ability for digital flow readout (in Sensorless mode) and communication to BMS • Future capabilities: • Digital flow readout in all control modes • Min./max. settings for pump flow output Readout accuracy +/- 5% = Brazil Visit 2012
- 35. Design Envelope IVS advantages Wiring VFD mounting bracket savings Potential wiring savings —with 30 kW motor and controls, the savings is estimated to be $340 per pump. Brazil Visit 2012
- 36. Design Envelope IVS Advantages Pump Starting • Provides a gentle ramp up or down in speed to eliminate the surges, mechanically, electrically, and hydraulically, caused by starting a motor • Monitors and protects the motor and cables Brazil Visit 2012
- 37. Design Envelope IVS Advantages Motor Starting Currents Design Envelope IVS Brazil Visit 2012
- 38. Design Envelope IVS Advantages Motor Starters 22kw, 460V Cost Peak Amp Draw Demand charge starter (35.1 A) ($5.60 per kW per 30 days) DOL $99 245.7A $633 Star/Delta $1,587 140.4A $362 Soft Start $1,155 98.3A $253 VFD $2,835 35.1A $90 $543 savings per month vs. constant speed DOL starting Brazil Visit 2012
- 39. Design Envelope IVS Advantages Harmonic Distortion 5HP • Design Envelope IVS pump controls include built-in DC line reactors (equivalent to 5% AC line reactors) • Other drives often need external AC reactors (for 30 HP estimated cost is $440): Mitsubishi, Hitachi, Lenze/AC Tech, Yaskawa*, Schneider, Eaton*, Siemens 125HP * Some models only External AC line reactors Brazil Visit 2012
- 40. Design Envelope IVS Advantages Emission and Immunity Requirements • Design Envelope IVS pumping unit controls include RFI filters to ensure compliance to low emission and immunity requirements EN61800-3 to the 1st environment class CI (EN55011 unrestricted sales class B). • Wall-mounted drives often do not include these and must be provided as an extra. Brazil Visit 2012
- 41. Design Envelope IVS Advantages Reflected Wave Voltage • If distance between the motor and the control is long, a standing wave can form between the motor and control • These waves can increase voltage at the motor terminals causing the motor insulation and bearings to fail prematurely • Locating the control with the motor will minimize this problem Brazil Visit 2012
- 42. Design Envelope IVS Advantages Envelope Selection Reduces Risk and Cost Savings on re-selections Recent project $25,000 during construction alone C A – Original design B – 2nd design B C – Final design A Brazil Visit 2012
- 43. Design Envelope IVS Advantages Energy Metering Capability • Use the Integrated Controls as an energy meter for energy measurement verification kWh readout Brazil Visit 2012
- 44. Design Envelope IVS – Values & Benefits Wall Space Savings No room on wall for multiple VFDs Brazil Visit 2012
- 45. Design Envelope IVS Advantages to First Cost Savings Example: 1000 USgpm at 90 ft Selection: 4300 0611-030.0 Design Envelope IVS First cost savings 1) Selections save energy and cost $1,230 2) Impeller trim saves energy and cost --- 3) Superior control (eliminate DP sensor) $2,700 4) Smaller size motor and control $930 5) Wiring VFD mounting bracket savings $340 6) Harmonic distortion $440 7) Emission and immunity requirements 8) Reflected wave voltage Savings 9) Envelope selection reduces risk and cost $500 equal 10) Energy metering capability 11) Saves Wall space $100 --- 75% of pump Cost to contractor of IVS pump = $8,350 Total $6,240 cost Only 3) above includes Sensorless control Brazil Visit 2012
- 46. Further Design Envelope pumping value vs. end suction pump • First cost savings • Pipe savings • Floor Space savings • Maintenance Savings • Savings on reselection VS. Brazil Visit 2012
- 47. End suction pump installation • Coupling re-alignment • Grouting • Inertia pad • Concrete base • Flex connectors Brazil Visit 2012
- 48. Design Envelope – values & benefits First cost savings 3 pump system 3 pump system VIL Horizontal Split Case 0611-030.0 150x120x300 Savings Installation $19,572 $8,327 cost $11,245 (=57%) Floor space 105.7 sq. ft 44.2 sq. ft $9,225 ($150 / sq. ft) Brazil Visit 2012
- 49. Design Envelope – values & benefits Floor space savings Brazil Visit 2012
- 50. Design Envelope – values & benefits Pipe savings (Glendale Arena, Phoenix) Less pipe = less friction loss resulting in operating cost savings: $6,600 (est. from TDH reduction) Savings Piping $225,975 $128,960 cost $97,015 (= 43%) Length 2751 ft 1723 ft of pipe (2751/100=27.51x (1723/100=17.23x 1028 ft 3’tdh=82.53’tdh) 3’tdh=51.69’tdh) Brazil Visit 2012
- 51. Design Envelope – values & benefits Maintenance savings (Edmonton Airport) $8200 annual savings due to faster mechanical seal changes Brazil Visit 2012
- 52. Design Envelope IVS – Why You Should Use It • Energy savings • First cost savings • Motor / control / sizing More than 20% • Pipe savings first cost savings • Floor space savings • Maintenance savings More than 30% • Wiring savings life cycle cost savings • Harmonic control savings • Sensorless savings on a 6” Design Envelope IVS pump compared to end-suction with VFD • Commissioning savings on wall (doesn’t include pipe savings) • Flow/energy metering • Savings on re-selections Brazil Visit 2012
Editor's Notes
- A flo-trex valve is a multi function valve that replaces an isolating valve, a non-return valve and also an elbow. The valve can also be used to throttle the pump to aid the system commissioning process. The valve has a 45 degree split and can be rotated to change an angled valve to a straight configuration or visa versa. So, now we have reviewed our installation options, lets take a look at a savings example…………….
- LEFT: BAYFRONT TOWERS, Tampa, FL Compact mechanical room with no space for two individual pumps and no space to mount drives on the wall. Simple single large AHU avoided using DP sensor by using sensorless design. Pumps also have auto alternating feature. Worked out of the box with only a slight adjustment to the minimum maintained pressure to accommodate the twin chillers minimum flow requirement. What is not shown in this picture is the two chillers and twin buffer capacity tanks and expansion control tank. There’s a lot of equipment in this little room! 4302 8x8x10-20 hp DualArm DE-IVS Sensorless unit we sold this past year. The DualArm IVS Sensorless pump has been in operation for almost ¾’s of a year. We took out an old water source Air Handler replacing it with a chilled water AHU, Twin Chillers, the IVS dual Arm, a buffer capacity tank, air purger and expansion tank all in the same room we took the old AHU out of…No small task. It worked right out of the box with only a slight adjustment to the minimum maintained pressure. The original set point was below the chillers minimum flow requirement. Otherwise – Flawless! RIGHT: SHOREWOOD PACKAGING, Danville, VA If no floor space, mount the pumps off the ground!! Commercial real estate cost $120/ sq ft, +50% Joe’s numbers on wall mounting?
- Armstrong Vertical inline pumps with Design Envelope IVS integrated controls. Series 4300 pumps are available up to 350 hp with integrated controls. Series 4380 close-coupled pumps are available up to 7.5 hp with integrated controls.
- Impeller trims are optimized to the motor power at the pump BEP. What exactly does that mean? It means we look for the intersection of the motor bhp line with the pump BEP and set our impeller trim to that motor. In this example, a 6x6x11.5 pump 40 hp uses an 11.50” impeller 30 hp uses a 11.44” impeller 25 hp uses a 10.78” impeller And a 20 hp uses a 10.00” impeller Any operating point in between the pre-set impeller trims is achieved by varying the speed. Why don’t we use the largest impeller?... This is the most efficient trim… This is true hydraulically. But through testing and experience, we found that the common asynchronous motor torque is not constant and at lower frequencies typically around 48Hz, the mechanical losses start to have an effect. Thus we have distinct impeller trims for each motor. Harmonics => 25/30 = 16.6% (no dollar cost per Danfoss) Total harmonic distortion reduction. *NOTE if anyone asks: impeller trims are based on water. For other fluids, the trim diameter is different.
- This page looks at the starting currents for an AC motor. Remember that the more abrupt and higher the current start, the greater the wire sizing, to handle the current, the greater the possibility of demand charges and the greater the threat of water hammer, and broken pipes. Direct-On-Line: or “across the line” is the oldest way to start a pump. The power required to start the pump can go as high as 700% as shown above. As the pump approaches 60Hz the current drops. Start/Delta : One method to control the current is to shift between the motor coil configurations. The Star configuration is used to start the motor. When the motor reaches close to maximum speed, say 45Hz, a relay switches the configuration from a Star to Delta. Soft-Starters : These devices can be either electric timers which monitor and limit the voltage or they can be electronic which monitors and limits the current. Since these devices only control the voltage or the current, many of them can not be used for long periods of time, and usually can not exceed 30 seconds. VFDs : Control both the frequency and the voltage simultaneously. This gives full control over the acceleration and deceleration ramps. This is the best method of starting or stopping a pump but it is also, in most applications, the most expensive.
- Peak amp draw = 35.1 FLA x start-up % kW = Peak amp draw x 460V / 1000 Demand charge = $/kW
- A long list of savings that adds up to a LCC and a true value based offering.
- In a 3 pump system shown here (NOTE: We don’t show the VFDs on the wall or integrated on the motor) But we eliminate the flex connectors, the concrete bases, inertia pads, no realignment of the flex coupling during commissioning. HSC versus VIL Assume 3 pump system - 6x5x12 versus 6x6x11.5 (2-duty / 1-standby) Installation cost = $19,572 vs $8,327 105.7 sf vs 44.2 sf; diff. = 61.5 sf and if we assume $150 / sf, that’s $9,225
- LEFT: BAYFRONT TOWERS, Tampa, FL Compact mechanical room with no space for two individual pumps and no space to mount drives on the wall. Simple single large AHU avoided using DP sensor by using sensorless design. Pumps also have auto alternating feature. Worked out of the box with only a slight adjustment to the minimum maintained pressure to accommodate the twin chillers minimum flow requirement. What is not shown in this picture is the two chillers and twin buffer capacity tanks and expansion control tank. There’s a lot of equipment in this little room! 4302 8x8x10-20 hp DualArm DE-IVS Sensorless unit we sold this past year. The DualArm IVS Sensorless pump has been in operation for almost ¾’s of a year. We took out an old water source Air Handler replacing it with a chilled water AHU, Twin Chillers, the IVS dual Arm, a buffer capacity tank, air purger and expansion tank all in the same room we took the old AHU out of…No small task. It worked right out of the box with only a slight adjustment to the minimum maintained pressure. The original set point was below the chillers minimum flow requirement. Otherwise – Flawless! RIGHT: SHOREWOOD PACKAGING, Danville, VA If no floor space, mount the pumps off the ground!! Commercial real estate cost $120/ sq ft, +50% Joe’s numbers on wall mounting?
- The VILs present a huge opportunity for pipe savings as they can be mounted directly to the chillers, boilers, and cooling towers. On average the pipe savings are reduced by 40-50%. Here’s an example of a plant room optimization for Glendale Arena, home of the Phoenix Coyotes. On the left are HSC. On the right the VILs are mounted directly onto the chillers saving 43% of piping. In this case, the pipe savings pretty well paid for the pumps. Ran AOL 2400 gpm @ 50 ft vs 2400 gpm @ 80 ft and looked at difference in op cost. 14477 vs 7893 = $6600.
- The most common replaced item on pumps is the mechanical seal. Seal changeout is much faster 30mins versus 2 hrs compared to base-mount. Also 4300 VILs don’t use bearings which dramatically reduces failures and maintenance costs.
- A long list of savings that adds up to a LCC and a true value based offering.