1. 1 Pumping System Fundamentals 2014 Jeff Turner Systecore Inc. www.systecoreinc.com www.michigansteam.com

2. 2 Overview Welcome Pumping Review Piping Review

3. 3 Back to the Basics!

4. 4 Pump Review Pump Sizing Pump Types Parallel Pumping Series Pumping Other Cautions

5. 5 Pumping Sizing PRO-MAX ® Series Pumps

6. 6 Affinity Laws

7. 7 How does it work? Full Trim Impeller...

8. 8 How does it work? Partially Trimmed Impeller...

9. 9 Affinity Laws Capacity varies as the ratio of the diameters. Head varies as the ratio of the square of the diameters. Brake horsepower varies as the ratio of the cube of the diameters.

10. 10 120 110100908070605040 3020 140 130 10 4 24 20 16 12 8 H.[FT] US.gpm 50% 60% 70% 75% 79% Adjustment of the Pumping Capacity Trimming Impellers? Why Not? Decreases Pump Efficiency One Way Trip VSD’s

11. 11 Affinity Laws

12. 12 Affinity Laws

13. 13 What’s on a Pump Curve? Flow, gpm Head, feet Efficiency curves Impeller trims Horsepower curves NPSH Curve Pump speed Non-overloading value, minimum flow

14. 14 Example Selection Point Flow = 1000 gpm Head = 90 feet What then? Pump Curve Booklet Software Websites Select: 5” End Suction Pump

15. 15

16. 16

17. 17 Detail Report - ‘Standard Efficiency’ Motor Centrifugal Pump - Detail Report Pump Series: HVES Pump Size: E4N11A-2 Performance Rank: 1 Pump Speed: 1750 Total Capacity: 1000.0 gpm Total Head: 90.0 Feet Efficiency: 85.8 pct NPSH req: 11.7 Feet Discharge Size: 4.000 in Velocity: 18.03 fps Suction Size: 6.000 in Velocity: 11.10 fps Impeller Diameter: 10.815" PRV Size: Max BHP: 30.00 (at design: 67.21 pct) Pump Power, BHP: 26.7 ( 21.99 Kw) Motor Power, HP: 40.00 (BHP/HP = 0.74) Choose ‘non-overloading’ motor

18. 18 Detail Report - ‘Standard Efficiency’ Motor

19. 19 Detail Report - ‘High Efficiency’ Motor Motor: Century E+ AC MOTOR 230/460V SCE S324T DPE E600 40.000 HP 1770 RPM 4 poles 60 Hz 3 phase Voltage: 460 RPM: 1784.31 Eff: 93.38 AMP: 35.31 P.F.: 83.70 KVA: 28.14 Annual Operating Cost: $20627.78 for 8760.0 hours annually at $0.10/Kwh

20. 20 Operating Cost Comparison Standard Efficiency$21,180 High Efficiency$20,628 Annual Savings$ 552 (@ $0.10/kWh)

21. 21 Pumping system Sources of pressure drop Pipe Fittings Valves Coils Source (boiler or chiller)

22. 22 System Curve Head varies as the square of the flow.

23. 23 Impeller Change/Flow, Percent 0 10 20 30 40 50 60 70 80 90 100 010203040 5060708090100 Percent of Design Head Head System Curve

24. 24 What Impacts the System Head? Actual component pressure drops Actual piping loses Present vs. future loads Safety Factors Heating vs. cooling flow

25. 25

26. 26 Jeff’s 1st Law Pumps are stupid. Pumps don’t know flow... Pumps don’t know temperature......it will deliver as much flow as it can based on the system resistance it sees.

27. 27 Pump Over-heading Balance System? Close Valve @ Pump? Trim the impeller? Adjustable Frequency Drive?

28. 28 Why Trim the Impeller? Centrifugal Pump - Detail Report Pump Series: HSC Pump Size: S5A12A-2 Performance Rank: 2 Pump Speed: 1750 Total Capacity: 1000.0 gpm Total Head: 55.0 Feet Efficiency: 77.58 pct NPSH req: 10.72 Feet Discharge Size: 4.000 in Velocity: 18.03 fps Suction Size: 6.000 in Velocity: 11.10 fps Impeller Diameter: 9.375" PRV Size: Max BHP: 18.19 (at design: 78.20 pct) Pump Power, BHP: 17.80 ( 13.39 Kw) Motor Power, HP: 20.00 (BHP/HP = 0.90)

29. 29 Standard efficiency Why Trim the Impeller?

30. 30 High efficiency Why Trim the Impeller? Motor: Century E+ AC MOTOR 230/460V SCE 256T DPE E401 20.000 HP 1700 RPM 4 poles 60 Hz 3 phase Voltage: 460 RPM: 1761.91 Eff: 90.28 AMP: 22.33 P.F.: 83.36 KVA: 17.79 Annual Operating Cost: $12991.58 for 8760.0 hours annually at $0.10/Kwh

31. 31 Operating Cost Comparison- High Efficiency Motor + Trimming Impeller Std Eff Hi EffDifference @100 Ft$21180 $20628 $552 @ 55 ft 13362 12992 $370 Difference$ 7818 $ 7636 $8188

32. 32 The Effects of Glycol on Pump Selection

33. 33 Sample Problem The calculations are based on 1,000 gpm of water to the process, and as such designed the system utilizing 8 inch pipe & 6410 feet of pipe. A 5” pump is selected for 1000 gpm @ 90 feet of head. The correct impeller size is 10.8125” and the correct motor is 30 hp, nol.

34. 8 in 1.56 6.42

35. 6410 1.56 100

36. 36 Centrifugal Pump - Detail Report Pump Series: HVES Pump Size: E4N11A-2 Performance Rank: 2 Pump Speed: 1750 Total Capacity: 1000.0 gpm Total Head: 90.0 Feet Efficiency: 85.8 pct NPSH req: 11.70 Feet Discharge Size: 4.000 in Velocity: 18.03 fps Suction Size: 6.000 in Velocity: 11.10 fps Impeller Diameter: 11.250" Max BHP: 30.00 (at design: 79.50 pct) Pump Power, BHP: 26.7 ( 23.54 Kw) Motor Power, HP: 40.00 (BHP/HP = 0.79) --------------------------------------------------------------------- Motor: Century E+ AC MOTOR 230/460V SCE S324T DPE E600 40.000 HP 1770 RPM 4 poles 60 Hz 3 phase Voltage: 460 RPM: 1783.06 Eff: 93.43 AMP: 37.29 P.F.: 84.79 KVA: 29.71 --------------------------------------------------------------------- Annual Operating Cost: $22070.62 for 8760.0 hours annually at $0.10/Kwh

37. 37 Sample Problem The new process requires fluid which is 50% propylene glycol at 45°F. What is the new head requirement? What is the new impeller and motor size for these conditions?

38. 45 50 1.05 13.21 0.00013542

39. 1000 8 in. 6.42 2.29

40. 6410 2.29 147

41. 41

42. Centrifugal Pump - Detail Report Pump Series: 1510 Pump Size: 5G Performance Rank: 1 Pump Speed: 1750 Total Capacity: 1000.0 gpm Total Head: 147.0 Feet Efficiency: 82.99 pct NPSH req: 8.07 Feet Discharge Size: 5.000 in Velocity: 16.03 fps Suction Size: 6.000 in Velocity: 11.10 fps Impeller Diameter: 12.625" Max BHP: 51.68 (at design: 67.94 pct) Pump Power, BHP: 44.720 ( 33.35 Kw) Motor Power, HP: 60.00 (BHP/HP = 0.75) --------------------------------------------------------------------- Motor: Century E+ AC MOTOR 460V SCE Y364T DPE E716 60.000 HP 1775 RPM 4 poles 60 Hz 3 phase Voltage: 460 RPM: 1776.13 Eff: 92.79 AMP: 52.21 P.F.: 86.40 KVA: 41.60 --------------------------------------------------------------------- Annual Operating Cost: $31482.63 for 8760.0 hours annually at $0.10/Kwh

43. 43 Sample Problem Results 5” pump must be selected for 1000 gpm @ 147 feet of head. The correct impeller size is 12.3125 inches and the correct motor is 60 horsepower (non-overloading).

44. 44 Parallel Pump Operation Total system head 1/2 system flow

45. 45 Two pumps in operation Each pump Head (ft) Flow (gpm) Parallel Pump Operation

46. 46 Parallel 6” Pump Curve

47. 47 90 80 70 60 50 40 30 20 10 0 100908070605040 3020 100 % Full Load HP % Flow Parallel C/S 2 Pumps Single C/S Single Parallel C/S Parallel Pump Operation

48. 48 Series Pump Operation Total system flow 1/2 system head per pump

49. 49 Flow (gpm) Two pumps in operation Head (ft) Single pump curve Series Pump Operation

50. 50 Flow (gpm) Two pumps in operation Each pump Head (ft) Series Pump Operation

51. 51 Pump Types

52. 52 Basemounted Vertical Inline Vertical Turbine Types of Pumps

53. 53 Typical Size Range by Pump Type

54. 54 Pump types: –Basemounted Long & Close coupled, end suction Horizontal Split case, double suction –Vertical Inline Close coupled Spacer coupled Centrifugal Pump Construction

55. 55 Type HVES Frame Mounted End Suction PRO-MAX ® Series Pumps Flows to 2,500 GPM Heads to 400 ft. TDH Delivery in 7 working days

56. 56 PRO-MAX ® Series Pumps Flows to 2,500 GPM Heads to 450 ft. TDH Delivery in 7 working days Space saving design Type HVES Close Coupled End Suction

57. 57 Type HSC Horizontal Split Case Flows to 6,000 GPM with larger ones on way Heads to 160 ft. TDH Optional 300 PSI W.P. Delivery in 7 working days PRO-MAX ® Series Pumps

58. 58 Type VIL - Vertical Inline Pumps (Close Coupled) PRO-MAX ® Series Pumps Flows to 2,500 GPM Heads to 450 ft. TDH Delivery in 7 working days Space saving design

59. 59 Lineshaft –88 Models –5-20” bowls –4 Styles –20 - 10,000 gpm –7 - 200 feet head Submersible –48 Models –5 - 14” bowls –40 - 2000 gpm –25 - 300 feet head Vertical Turbine Pumps

60. 60 Important considerations: –Manufacturing standards/Quality (ISO 9001) –Serviceability, maintenance after turnover of project –Availability of replacement parts/motors –Effect of pump on system efficiency, flexibility for reconfiguration for future use. –ASHRAE 90.1 - optimizing energy use of pump –Pricing comparison between Basemount & V-I-L, an understanding the necessities for maintenance friendliness. Centrifugal Pump Construction

61. 61 Important considerations: –Hytrel (orange) versus EPDM (black) Couplers –ANSI/OSHA Coupling Guard –HVAC Pumps Centrifugal Pump Construction

62. 62 29 Recommended installation: –Basemount –Tie in with finished floor Centrifugal Pump Construction

63. 63 31 Recommended installation: –Basemount –Tie-in with finished floor impractical –Spring/RSR isolation Centrifugal Pump Construction

64. 64 Piping Review Why Variable Volume Primary-Secondary Piping Air Management Primary-Secondary Variations

65. 65 Why Variable Volume? 3-Way Valve Systems:

66. 66 Variable Volume Systems Permit Constant Volume Chiller Pumping Permit Variable Volume Load Pumping

67. 67 Primary-secondary Pumping Return Supply Pump Controller Constant or Variable Speed Secondary Pumps Primary- secondary Common Chiller 3 Chiller 2Chiller 1 Constant Speed Primary Pumps Air Separator and Expansion Tank(s)

68. 68 Jeff’s 2nd Law More Pumps is Better!

69. 69 HD 125 100 75 50 25 150 255075100 % Design Flow Primary Pumps = V/V Secondary Pumps + Constant Flow Primary Pumps, only Pump Head Comparison

70. 70 Pressure Absorbed by 2-way Valves

71. 71 Graphical AOC Cost Comparison

72. 72 Primary-secondary Pumping Return Supply Pump Controller Constant or Variable Speed Secondary Pumps Primary- secondary Common Chiller 3 Chiller 2Chiller 1 Constant Speed Primary Pumps Air Separator and Expansion Tank(s)

73. 73 How does P-S Work? Supply C H I L L E R C H I L L E R C H I L L E R Return Primary-Secondary Common Primary Loop (Production) Secondary Loop (Distribution)

74. 74 Common Pipe Design Supply Primary Loop (Production) Secondary Loop (Distribution) Primary-secondary Common Chiller 3 Pipe Diameters, Minimum Length Friction Loss < 1.5 ft Return Equal Diameter Balance and Check Valve

75. 75 Common Pipe Design Overall Pressure drop in the common pipe shall not exceed 1.5 ft. A distance of 3 pipe diameters between the common tees is desirable. The velocity of the secondary return should not exceed 5 fps.

76. 76 How does P-S Work? Primary Flow = Secondary Flow Secondary Flow > Primary Flow Primary Flow > Secondary Flow C H I L L E R C H I L L E R C H I L L E R Return Primary-secondary Common Supply Primary Loop (Production) Secondary Loop (Distribution)

77. 77 Front Loaded Common Chiller 2, off Chiller 1, on

78. 78 Common --No Flow Secondary Pumps 1500 0 CHWS Temp 45 o F CHWR Temp 55 o F ECW Temp 55 o F 1500 Chiller 2, off Chiller 1, on Production Flow = Distribution Flow

79. 79 CHWS Temp Common -- 500 Secondary Pumps 1500 2000 1500 2000 0 47.5 o F CHWR Temp 55 o F ECW Temp 55 o F Mixing (1500 @ 45) + (500 @ 55) Chiller 2, off Chiller 1, on 2000 Distribution > Production

80. 80 Increasing Supply Water Temperature - How Serious? Coil Selection - additional rows. Series Chiller - for the critical load. Chiller Temperature Reset... –1 to 3 % increase in operating cost per degree of reset.

81. 81 Common -- 900 Secondary Pumps 3000 2100 1500 2100 1500 CHWS Temp 45 o F CHWR Temp 55 o F ECW Temp 52 o F Mixing (2100 @ 55) + (900 @ 45) (Flow in GPM) P/S Chiller Bridge - Front Loaded Common Chiller1, on Chiller 2, on Production > Distribution

82. 82 Step Function Linear Function Return Primary/Secondary Common Supply Production Distribution Chiller 3 Chiller 2 Chiller 1 Primary-Secondary Relationship

83. 83 Typical Load Profile

84. 84 % Load % Time 100 80 60 40 20 100755025 Chiller 1 Chiller 2 1 1 22 Chiller 2, 60% Chiller 1, 40% Applying a 60/40 Chiller Split

85. 85 % Load Time Approaching Flow = Load

86. 86 Chiller Sequencing From Loads Common Pipe To Loads Production Secondary Pumps Distribution Chiller 2, off Chiller 1, on FSFS T S-S T S-R Chiller 3, off Primary Pumps T P-S T P-R FPFP

87. 87 Back Loaded Common Secondary Pumps Chiller 2, off Chiller 1, on 1500

88. 88 Common 0 Flow Secondary Pumps 1500 CHWS Temp 45 o F CHWR Temp 55 o F Chiller 2, off Chiller 1, on 1500 Production = Distribution

89. 89 Common 500 gpm Secondary Pumps 1500 2000 1500 2000 0 CHWS Temp 47.5 o F CHWR Temp 55 o F 500 Mixing (1500 @ 45) + (500 @ 55) 500 Chiller 1, on Chiller 2, off Distribution > Production

90. 90 Production > Distribution

91. 91 Applying a Variable Speed Chiller

92. 92 Hybrid Chiller Plant Primary- Secondary Common Return Supply Secondary Constant Speed Pumps Chiller 3Chiller 2Chiller 1

93. 93 Air Management Air Removal versus Air Control

94. 94 Types of Tanks Compression Tank Diaphragm Bladder

95. 95 Compression Tank System Connection

96. 96 Diaphragm Tank System Connection Air Charge

97. 97 Bladder Tank System Connection Air Charge

98. 98 Standard Tank Installation Tank Fitting PRV from system to system Rolairtrol Lock Shield Valve Pitch up PNPC

99. 99 Diaphragm Tank Installation System Vent Rolairtrol From System Vent Diaphragm Tank Thermal Loop Lock Shield Valve PNPC To System

100. 100 Standard or Diaphragm Tanks? Standard Water and air in contact May be larger, heavier Require tank fittings Rarely require repair Low initial cost Diaphragm/Bladder Impermeable barrier Probably smaller Require vents and thermal loop Repair difficult or impossible Higher initial cost

101. 101 Pumping Away Chiller 3Chiller 2Chiller 1 Air Separator and Expansion Tank(s)

102. 102 Tank Location Air Water Compression Tank Pump System Point of No Pressure Change

103. 103 Pumping Away from the Tank System Pressure Pump Off Pump On Pump Pressure Difference PNPC Keep Short

104. 104 Pumping Toward the Tank System Pressure Pump Off Pump On Pump Pressure Difference PNPC

105. 105 Types of HVAC Pumping Systems 1. Primary-Secondary Pumped –Direct Return –Reverse Return 2. Primary-Secondary-Tertiary Pumped 3. Primary-Secondary-Tertiary Hybrid Pumped 4. Primary-Secondary Zone Pumped 5. Primary V/S Pumped

106. 106 C H I L L E R C H I L L E R C H I L L E R Return Supply Pump Controller Secondary Pumps 1. Two Pipe Direct Return

107. 107 Primary-Secondary Pumped

108. 108 1a. Two Pipe Reverse Return

109. 109 P-S with Reverse Return

110. 110 Primary-secondary Variations 1. Primary-Secondary-Tertiary Pumped 2. Primary-Secondary-Tertiary Hybrid Pumped 3. Primary-Secondary Zone Pumped 4. Primary Variable Speed Pumped

111. 111 2. Primary-Secondary-Tertiary C H I L L E R C H I L L E R Zone A Zone B Zone C Optional Variable Speed Pump DP Sensor Modulating Control Valves Secondary Pumps C H I L L E R Primary Pumps Tertiary Pumps Common Pipe Common Pipe

112. 112 Tertiary Zone T3 T1 Load MV Load MV Load MV Common Pipe T2 Tertiary Zone Pump Tertiary Bridge Secondary Pump(s) Secondary Chilled Water Return Small Bypass Maintains Accurate Temperature Reading

113. 113 3-way valve application

114. 114 Three-way Valve System

115. 115 Multi-zone application

116. 116 District cooling application Individual building temperature control Static pressure isolation Return water temperature control Btuh Totalization Outdoor temperature reset Independent operation

117. 117 District cooling application with GPX Independent pressure control Building operation isolation HVAC fluid isolation

118. 118 Primary-Secondary-Tertiary

119. 119 3. Primary-Secondary-Tertiary Hybrid

120. 120 Primary-Secondary-Tertiary Hybrid

121. 121 Parallel Pump Curves

122. 122 Variable Speed Pump Curve

123. 123 Tertiary Pump Bypass Piping Tertiary Pump Secondary Supply Secondary Return Common Low Pressure Drop Valve N/C N/O

124. 124 C H I L L E R C H I L L E R Return Supply Common Primary Secondary Constant Speed Chiller Pumps VS Zone Pump Circuit Setter VS Zone Pump VS Zone Pump 4. Primary-Secondary Zone Pumping

125. 125 Shared Piping

126. 126 Primary-Secondary Zone Pumped

127. 127 Primary Variable Speed Pumping AFD C H I L L E R C H I L L E R C H I L L E R Flow Meter Modulating Control Valve Two-position Control Valves DP Sensor Controller

128. 128 AFD C H I L L E R C H I L L E R C H I L L E R Flow Meter, option Modulating Valve Two-position Control Valves DP Sensor Controller DP Sensor Primary Variable Speed Pumping

129. 129 Design Considerations Size Bypass for Minimum Flow of Largest Chiller. Size Bypass Modulating Valve for Zone  P. Size Chiller  P Sensor for Minimum Chiller Flow. Sequence Chillers Based on  P Switch or Temperature.

130. 130 Consider this design if: System flow can be reduced by 30%. System can tolerate modest change in water temperature. Operators are well trained. Demonstrates a greater cost savings. High % of hours is at: –Part load. –Full load with low entering condenser water.

131. 131 Do not use if: Supply temperature is critical. Constant volume. Existing controls are old or inaccurate. Operator unlikely to operate as designed. System is noise sensitive.

132. 132 Primary Variable Speed Cautions System Volume Rate of Change Turn-down Ratio Chiller Selection Pump Selection Supply Water Temperature Controls Complexity Sensor Calibration Operator Ability

133. 133 System Volume Dictates impact of rate of flow change. Chiller protection. –Freeze up. –Trip out.

134. 134 Rate of Change Trane: –30% per minute flow change. –10% per minute flow change. York: STR = System Volume  Design Flow –If greater that 15, 100% to 50% in 15 minutes. –If less than 15, 100% to 50% in 15 + (15 - STR) minutes.

135. 135 Turn-down Ratio Chiller manufacturers publish 3 - 11 fps flow range. Nominal base of 7 fps desirable. Variation of  1 to 2 fps. Type and brand.

136. 136 Chiller Selection Equal size chillers. –Redundancy. –Parts. –Maintenance. Unequal size chillers. –Control issues. –Flow issues –Additional equipment.

137. 137 Pump Selection Equal size pumps. –Redundancy. –Parts. –Maintenance. Unequal size pumps. –Control issues. –Flow issues. –Premature failure.

138. 138 Supply Water Temperature Dependant on : –System volume. –Rate of flow change. Application specific.

139. 139 Controls Complexity Additional controls for the chillers Additional controls the pumps. Pumps operate on flow, temperature, and  P. Chiller  P.

140. 140 Sensor Calibration Multi-sensor control: –Flow. –Temperature. –  P. Maintenance. Calibration.

141. 141 Operator Ability Within operators ability?. Training is mandatory. –Initial –Periodic. Systems too complex?

142. 142 Problems in the Field Difficulty in system control. Chiller stability. Laminar flow - heat transfer issues. Flow confirmation. Real world.

143. 143 Primary Variable Speed Pumping

144. 144 Sensor Location and Pump Sequencing

145. 145 Return Supply Pump Controller AFDs Differential Pressure Sensor Chiller 3 Chiller 2Chiller 1 Sensor Location

146. 146 Return Supply Variable Head Loss Constant Head Loss Pump Controller AFDs Differential Pressure Sensor Chiller 3 Chiller 2 Chiller 1 Maximizing Variable Head Loss

147. 147 Control Area Example

148. 148  P AB+EF 20FT  P Zone 1 20FT  P BC+DE 20FT  P Zone 2 20FT  TDH = P AB + EF + BC + DE +  P ZONE 2 = 60 FT Pressure Drops in Piping (Table 11-1)

149. 149 Control Area Calculation

150. 150 Control Area Curve

151. 151 Applying Multiple Sensors

152. 152 Return Supply Pump Controller AFDs Chiller 3 Chiller 2Chiller 1 WRONG! Single Point Pressure Sensor Single Point Pressure Sensor

153. 153 Single Point Pressure Sensor

154. 154 Staging Variable Speed Pumps in Parallel 1. Pump Speed 2. End-of-Curve Protection 3. Efficiency Optimization

155. 155 Staging Based on Pump Speed A lag pump is staged on after the lead pump in reaches full speed. The pumps then operate in parallel, varying their speed together. As load decreases, the lag pump is destaged and the lead pump maintains setpoint once again. Required transmitter(s): Zone differential pressure only.

157. 157 End of Curve Protection As the lead pump increases in speed, there may be a point prior to reaching full speed where the single pump could operate off its published end of curve. Rather than allow this to occur, the lag pump is staged on so as to share the flow requirements. Required transmitter(s): Zone differential pressure and a flow meter.

159. 159 System Efficiency Optimization As the speed of the lead pump increases in relation to load, the overall efficiency of the pumping system (pump, motor, drive) also changes. For any given system there may be a range in speed where it is more efficient to run multiple pumps in parallel even though one pump could satisfy the load without end of curve concerns. Required transmitters: Zone differential pressure, flow meter, kilowatt meter, and system differential pressure transmitter.