ashrae 90.1 and the future of pumping part 2
TRANSCRIPT
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Further Design Envelope pumping valuevs. end suction pump
• First cost savings • Pipe savings• Floor Space savings• Maintenance Savings• Savings on reselection
VS.
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End suction pump installation
• Coupling re-alignment
• Grouting• Inertia pad• Concrete base• Flex connectors
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Design Envelope – values & benefitsFirst cost savings
3 pump system Horizontal Split Case 150x120x300
3 pump system VIL 0611-030.0
SavingsInstallation cost
$19,572 $8,327 $11,245(=57%)
Floor space
105.7 sq. ft 44.2 sq. ft $9,225($150 / sq.
ft)
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Design Envelope – values & benefitsFloor space savings
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Design Envelope – values & benefitsPipe savings (Glendale Arena, Phoenix)
Less pipe = less friction lossresulting in operating cost savings:
$6,600(est. from TDH reduction)
SavingsPiping cost
$225,975 $128,960 $97,015(= 43%)
Length of pipe
2751 ft(2751/100=27.51
x3’tdh=82.53’td
h)
1723 ft(1723/100=17.23x3’tdh=51.69’tdh)
1028 ft
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Design Envelope – values & benefitsMaintenance savings (Edmonton Airport)
$8200 annual savings due to faster mechanical seal changes
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• Energy savings• First cost savings • Motor / control / sizing• Pipe savings• Floor space savings• Maintenance savings• Wiring savings• Harmonic control savings• Sensorless savings• Commissioning savings• Flow/energy metering• Savings on re-selections
More than 20% first cost savings
More than 30% life cycle cost savings
on a 6” Design Envelope IVS pump compared to end-suction with VFD on wall (doesn’t include pipe savings)
Design Envelope IVS – Why You Should Use It
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Legislative Compliance
• Design Envelope IVS (DIN / IEC configuration) pumps conform
to 2013 AND 2015 requirements in Europe (MEI 0.4)
• Motor control combination is 2017 legislation compliant
• Constant speed circulators are generally illegal in Europe ( 20
to 2500) beginning January 2013
• DOE in USA has indicated it’s intension to legislate pump
efficiency
• My prediction is constant speed pumping will be illegal in
the future
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Integrated to 350hpStandalone 400-1250hp
4300
Design Envelope IVS Pumping Suite
Integrated to 125hp
Indoors
Outdoors
to 100hp
4302
to 100hp
to 7.5hp
4380
to 7.5hp
to 7.5hp
4382
to 7.5hp
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Introduction
DualArm / Twin Pump = 2 rotating assemblies
in 1 casing
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Differences from dualARM
Twin DualARM
Casings
Valve handles & locking mechanism on both suction and discharge
No handles – flapper on discharge only
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Differences dualARM / Twin
Hydraulics Duty-standby operation
Parallel operation
Oversized ports
Isolationvalve
Servicing
● up to 1,300 gpm● up to 120 ft● up to 40 hp
Blank plate
required
● up to 1,500 gpm● up to 400 ft● up to 100 hp Valve
isolation
Twin
dualARM
Functionality
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Differences from dualARM
Twin DualARM
Servicing
Valve isolation
Use handles to lock
Blanking plate
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Twin or dualARM – Which one to use?
Feature Twin DualARM
Redundancy
Parallel operation Critical service no down-time
High pressure
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Key values & benefits
•Redundancy•Compact•Installation savings
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Key values & benefitsRedundancy
• HVAC pump systems are typically designed as N+1 (where N = number of pumps)
• The “+1” is to ensure redundancy
• These systems operate in duty-standby mode only
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Key values & benefitsCompact
• One of the smallest footprints in the industry compared to other pump configurations
• In some units, flange-to-flange is less than a single VIL
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Twin pump – values & benefitsFloor space savings
Twin
dualARM
VILs
End suctions
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Twin pump – values & benefitsFloor space savings
ModelFootprint (sq-
ft)Ratio to end
suction pump
4030 3x2.5x8w/ 5hp motor 25.0 1.00
4300 0308-005.0 10.9 0.44
4302 0408-005.0 8.7 0.35
4312 0308-005.0 6.4 0.26Twin
dualARM
2 VILs
2 End suctions
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Twin pump – values & benefitsInstallation savings
No coupling re-alignment
No grouting
No inertia base
No concrete pad
No flex connectors
SavingsInstallation cost
$5,136 $2,010 $3,126(= 61%)
Floor space 25.0 sq. ft 6.4 sq. ft $2,790($150 / sq. ft)
2 pump system End Suction units 3x2.5x8
1 Design Envelope IVS Twin pumping unit 4312 0308-005.0
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Differences from dualARM
Price Footprint
1.10 0.60
1.50 0.80
1.00 1.00
Twin
dualARM
2 VILs
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Sensorless Agenda
• Traditional control with sensors• Sensorless control
• Introduction • Factory loading of program map• Benefits of Sensorless control over sensors
• Sensorless in action (video)• Case study – Canada Square Building Retrofit
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Design Envelope – Sensorless Control
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Pump, VFD, and sensor to control HVAC systems
Traditional Control with Differential Pressure Sensor
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Traditional Control with Differential Pressure Sensor
Possible sensor locations1)Mechanical room2)Remote load3)Other
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Sensor Location – In Mechanical Room(Variable Flow Secondary)
Local Differential Pressure sensor (In Mech Room)
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Sensor Location – In Mechanical Room
Sensor
Return
Supply
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Head
Design Flow
Min
. H
ead
System
Design Speed
AB
Design Point
Minimum Head
Pumps
Cooling coils (Typical)
Minimum Head equates to sensor setting across the pump in traditional system
with DP sensor
50% Load Speed
50% Load Flow
Operating Curve
Sensor Location – In Mechanical Room
A
B
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Sensor Location – Remote Load
Remote Differential Pressure sensor (Most remote load)
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Head
Design Flow
Min
. H
ead
System
Design Speed
A
B
Minimum Head equates to sensor setting at remote cooling coil in traditional system
50% Load Speed
50% Load Flow
Operating Curve
Control Curve
Sensor location – Remote load
Pumps
Cooling coils (Typical)
with DP sensor
Design Point
Minimum Head
A
B
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Design Envelope – Values & BenefitsOperating Cost Savings
Power Energy Savings
32.03Incremental
Cumulative
Constant speed throttled
Reduced speed unthrottled – constant flow
Reduced constant speed – variable flow
Variable speed – variable flow – Mech. Room SensorDesign Envelope sensorless
27.11
19.36
7.32
14.35
15%
29%
49%
26%
15%
40%
77%
55%
A
B
C
D
E
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Total Cost = Operating Cost (3 yrs) + First Cost
Design Envelope IVSOperating Cost Savings
Design Envelope Savings:
More than 60% vs. throttled
More than 35% vs. mech. room sensorD
esig
n
En
velo
pe
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Sensorless Control
Sensorless controlFeatured on Armstrong Design Envelope pumps
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Sensorless Control
Mimics the performance of a sensor by pre-programming pump curve characteristics into the IVS controls
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Sensorless Control
Works based on 4 parameters
•Power•Speed•Head•Flow
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Sensorless Program Mapping
•Power, speed, flow and head are recorded from pump test.
•All Sensorless data from every pump is recorded and kept on file in database
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40
60
80
100
120
Head
(ft
)
0 0.2 0.6 0.8 1 1.6
Flow (1,000 usgpm)
1848 rpm
30 hp
Series 4300Design Envelope 0611-030.06x6x11.5 @ 11.44 in
57 68 7782
8485
84
68
20
Control curve
1621 rpm
528 rpm
8277
140
160
0.4 1.41.2
Sensorless Program Mapping
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Sensorless Program Mapping
Design Envelope Series 4300 0611-030.0Design point = 1000 gpm at 80 ft
Flow (gpm)
Head (ft)
Power (bhp)
Frequency(Hz)
1000 80.0 25.2 55.3
900 70.9 19.8 51.2
800 62.7 15.2 47.3
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Sensorless Control – Detailed
Head
Flow
Pow
er
12
S1
S2
Original System
Curve
Control Curve
S1 System Curve
S2 System Curve
P1
P2
Operating point is wherever pump performance curve intersects system resistance curve
TraditionalSensorless Control
Operating point is where pump performance, system resistance and control curves converge
1 Satisfied Flow & Head Operating Point (S1 System Curve)
P1 Power at current flow & head
S1 Operating Speed pump curve
2 Satisfied Flow & Head Operating Point (S2 System Curve)
S2 Operating Speed pump curve
P2 Power at current flow & head
How do we get from 1 to 2?
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Sensorless control – detailed
System has CV modulating closed resulting in a steeper S2 system curve
Speed is stable at 1 until system control valves (CV) modulate.
Original System
Curve
1
2
S1
S2
Control Curve
S1 System Curve
S2 System Curve
Control Curve
Reverses as CVs open
Flow (gpm)
Head (ft)
Power
(bhp)
Freq.(Hz)
1000 80.0 25.2 55.3
900 70.9 19.8 51.2
Constant speed
900 88.0 23.8 55.3
Sensorless data
How we get from 1 to 2
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Adjusting Sensorless On Site
3 parameters to adjust Sensorless control curve on site
Head
Flow
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Sensorless on site
Payback on pump starts as soon as it is installed; no need to wait months for controls contractor
4300 0611-030.0Cost of pump = $9,702 USDAssume $0.10/kWhVariable flow-constant sp. op = $10,312/yrVariable flow-variable sp. op = $6,145/yrSavings = $4,167/yr
3 month savings = $1,389
Or 14% of the pump cost!
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Sensorless for parallel pumping
Currently only available for single pump operation systems
Sensorless for parallel pumping systems…
Coming soon
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Case Study: Canada Square Building Retrofit
Background•Constructed in 1972•18 floor office tower•37,000 m2 of commercial office space.•Armstrong supplied the VIL pumps for initial construction
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• Original pumps 4300 6G 1700 gpm at 140 ft, 75 hp
• Design Envelope 4300 IVS 1700 gpm at 136 ft, 75 hp
• Design Envelope IVS allowed designer to match pump performance to actual system conditions.
Actual system HDesign = 85 ft (53Hz)
• Design Envelope IVS pump provided 50% energy savings
• Cost savings of $38,000 per year
Case Study: Canada Square Building Retrofit Execution
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Summary of Sensorless Benefits
• Energy savings of 49% over mechanical room sensor• Reduces installation time & cost
• No wiring• No conduit• Savings of $2000
• Eliminates potential problems with sensors• Sensor failure• Calibration• Forgetting where it is located
• Easy on-site balancing and immediate energy savings• Readjust the setpoint from the IVS• No wait for controls commissioning
• Ideal for retrofit projects• Can send Sensorless data to the BMS
Intelligence for your pumping system
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King’s Yard Energy Centre / Olympic Park
London, UK
Design Envelope IVS PumpingAround the World
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ASHRAE 90.1 and Armstrong Solutions
ASHRAE 90.1 Armstrong Solution
Proportional Balancing • Design Envelope Pumps with • Easy adjustment of design head • Armstrong balancing valves• Flo-Trex Valves
• Throttling IF and WHEN needed (saves expensive retrofit)
Need to achieve 70% less power at 50% flow in CW pumping Systems
• Design Envelope Pumps with• Correct lowest operating cost
selections• Easy control
• Sensorless• Armstrong controls• BMS• Sensored
Larger Pipe Avoided With Design Envelope Pumps
All Pumps over 1 HP (3/4 kw) should have integrated controls!
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Design Envelope Pressure Boosters
• Lowest Energy• VMS more efficiency than single
stage• Utilizes suction design over
design for energy savings• Pressure set back
• Lowest life cost• Flush valves lasted longer due
to lower constant pressures • Slower speed and pressure
swings improves equipment life, reduced maintenance and noise from slower speeds, no pressure swings / PRV’s
• Security -Safe fill mode• No bypass maintenance -Design
Envelope Booster has electronic control
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Design Envelope IVS Pumping
•ASHRAE 90.1 Conformance • PLUS•Lowest Installed Cost•Lowest Life Cycle Cost
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Summary• Design Envelope thinking• All pumping should have integrated
controls. (constant speed pumping is obsolete and soon to be illegal)
• HVAC and Pressure booster pumps
• Design Envelope pumps are selected to right of pump best efficiency point in a simplified / risk free method
• Use Vertical Inline pumps, suction guides and Flotrex valves
• Twin and DualArm provide even lower cost and space
• If conventional controls valves used – Use manual balancing valves
•Lowest first cost•Lowest energy and life cost