1 Variable Speed Pumping in Hydronic Systems • Why use VFD or VSD Pumps? • What are they and how do they work • Back to the basics – reading constant speed curves • Basics – Understanding trimmed impeller curves • Basics – Understanding multiple speed curves • Basics – Understanding VFD curves • Applications – when and where to use VFD’s • Questions Engineering Presentation
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1 Variable Speed Pumping in Hydronic Systems Why use VFD or VSD Pumps? What are they and how do they work Back to the basics – reading constant speed curves.
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Variable Speed Pumping in Hydronic Systems
• Why use VFD or VSD Pumps?
• What are they and how do they work• Back to the basics – reading constant speed curves
• Basics – Understanding trimmed impeller curves
• Basics – Understanding multiple speed curves
• Basics – Understanding VFD curves
• Applications – when and where to use VFD’s
• Questions
Engineering Presentation
It is very often a 98% efficient boiler is placed in a 20% efficient system resulting in little to no savings in energy consumption.
We suggest putting your energy toward balancing production (boilers) with consumption (Air Handling Units, fin tube radiation, etc) by providing the proper distribution (pumping and balance).
ECM technology with wire to water savings up to 80%, at very effective cost points with Variable Speed, ECM motor and system control built into the pump itself.
These pumps are the one stop solution to system efficiency, correcting the system and distribution efficiency with boiler efficiency.
Patterson Pumps has excelled in their design and efficiencies offering better design point operating efficiency; most often offering a step down in HP for identical flow and head applications resulting in higher wire to water efficiency in addition to improving the system efficiency.
We have paired Premium Efficient Pumps with Premium Efficient Motors with the Cloud line of Variable Speed Drives.
ConsumptionProductionDistributionVariable Speed PumpingVariable Volume PumpingCv’s / GPM of Coil or slightly greater 1#Coils etc / Importance of Flow Limiting Cv =gpm/delta P square root
Train
Transition period (coldest Transition period (coldest design day)design day)
For the coldest day of the year ~2 % of the total operating period
Transition periodTransition period
But how is the system working during the remaining 98 % of the operating period?
Transition periodTransition period with standard Pumps with standard PumpsOversizing causes by worst case situationOversizing causes by worst case situation
Q
H
Duty point on coldest day of the year
Transition period Increase of the pumping head / system noises possibleUnnecessary energy consumption
H = Pumping Head HPU
Q = Flowrate VPU
200 gpm = 2,000,000 Btu/Hr 500 x 20
300 gpm = 2,000,000 Btu/Hr 500 x 15
400 gpm = 2,000,000 Btu/Hr 500 x 10
Checking the system Delta T can suggest the system Load
Checking the Boiler Delta T vs gas consumption gives the real efficiency.
System Curve vs the Pump curve.
Variable Speed Pumping in Hydronic Systems
Why use VFD’s?Global Studies Carried out by the European Commission
• Pumping systems account for 22% of the world’s electrical power demand
• Air Compressors 18%, Fans 16%, Cooling Compressors 7%, Other equipment 37%
• In some industrial plants pumps account for over 50% of the electrical load
• Rotodynamic (centrifugal) pumps account for 73% of all pumps
• Positive displacement (usually piston or screw types) account for 27%
• Over 95% of all pumps are oversized due to multiple butt covering!
• Up to 90% energy savings can be achieved using proper VFD techniques
• The pump can run closer to it’s Best Efficiency Point more frequently
The result of the effect of the Affinity Law is if we can operate a 125 Hp pump at half it’s speed and maintain the desired result of
it’s overall function it consumes only 5 Hp!
Pumps save electrical energy by properly applying them, check the HP of 200 gpm @ 45’ vs the HP of 200 gpm @ 12’.
This is really nice.
Now check out the Boiler operating at 30% vs. the Boiler operating at 85 – 95% Efficient.
Really Really REALLY NICE Savings.
Variable Speed PumpingWhy use VFD’s?
• Impeller hydraulic forces are reduced with the square of the speed change
• Bearing life is proportional to the SEVENTH power of the speed change
H = Safety margin when calculating piping means ~ 30% less current consumed
Safety Margin When Calculating PipingSafety Margin When Calculating PipingOversizing caused by friction loss safety factorsOversizing caused by friction loss safety factors
Flowrate Q
Flowrate Q
Flow velocity v
Hea
d
H
Re q
ui r
e d p
ow
e r
P
planned piping duty curve
planned operating point
actual piping duty curve
H
Power saving P
A
A
actual operating pointB
B
corrected operating pointC
C
1201101009080706050403020 14013010
4
24
20
16
12
8
H.[FT]
US.gpm
50%60%
70%
70%
75%
75%
79%
Adjustment of the Pumping CapacityTrimming Impellers?
Why Not?
• Decreases Pump Efficiency
• One Way Trip
Pu
mp
ing
He
ad
H F
t
Adjustment of the Pumping Adjustment of the Pumping CapacityCapacity
Changing the speed – manual multiple speed
H2
Q2 Volume Flow Q USGPM
n1
Q1
H1 n2
P1 n1
P2 n2
)(3
H1 n1
H2 n2
)(2
=
Q1 n1
Q2 n2
=
Adjustment of the Pumping Adjustment of the Pumping CapacityCapacity
Changing the speed – the VFD way! P
um
pin
g H
ea
d H
%
Volume Flow Q USGPM
1,0 • n
0,9 • n
0,8 • n
0,7 • n
0,6 • n
0,5 • n
0,4 • n
100
93
81
64
49
36
25
speed at 60 Hz
speed at 50 Hz
speed at approx. 40 Hz
Speed ControlSpeed ControlElectronic continuous speed control (Constant Pressure)
◦Automatic differential pressure control
Pu
mp
ing
He
ad
H F
t
Volume Flow Q USGPMQ2
H2
nmax
non-regulated pump
1
2
3
1. The sensor determined the actual pumping head. (actual value)
2. The electronic discerned the difference between the set value (point 1) and the actual value. (point 2)
3. The controller reduced the speed and moves the pumping head at the actual value now. (point 3)
H1
Q1
Speed Control StrategiesSpeed Control Strategies
Electronic continuous speed control
◦ control modes ∆p-c differential pressure constant ∆p-v differential pressure variable (max head
is twice min head) ∆p-T temperature guided differential pressure
control ∆p-cv combination from differential pressure
constant (second and third area of characteristic) and differential pressure variable (first area of characteristics)
◦ Operation modes Automatic night setback (let down function) manual regulator DDC (Direct Digital Control)
Speed Control ComparisonsSpeed Control ComparisonsComparison of the power consumption
max.-characteristic (non-regulated)
p constantp variable
po
we
r d
raw
P1 W
volume flow Q m³/h
““Delta PC” vs “Delta PV” ???Delta PC” vs “Delta PV” ???
Q
H
Δpv
Δpc Saves energy, because the load-controlledpump adjusts to system changes
Delta PC or Constant Pressure (differential)
Delta PV or Pressure Variant (max head twice min)
Speed Control MethodsSpeed Control Methods∆p-c differential pressure constant
◦Constant Pressure Differential Across the Pump (Hset value )
◦If the inlet pressure consistant (pump away from the tank) this operates like a pressure setpoint pump
◦Excellent in low friction loss systems (flat friction loss curves)
◦Independent of the number of the opened thermostatic valves
Speed Control MethodSpeed Control Method
∆p-c differential pressure constant
Volume Flow Q USGPM
Pu
mp
ing
He
ad
H F
t
∆p-c
nmax
1
2
ncontrolled
3Hset value
Hset value-min
p-c
Typical Heating Pipe System with Typical Heating Pipe System with p-c p-c Pump ControlPump Control
value of the pump is changing linear between Hset value and ½ Hset value .
◦Used in high friction loss systems with steep friction loss curves
◦The required differential pressure decreases rapidly with less flow
Speed Control MethodsSpeed Control Methods
∆p-v differential pressure variable
Volume Flow Q USGPM
Pu
mp
ing
He
ad
H F
t
nmax
1
2
ncontrolled
3
½ Hset value
Hset value-min
p-vHset value
Typical Heating Pipe System with Typical Heating Pipe System with p-v p-v Pump ControlPump Control
H[m]
4
3
2
1
00 1 2 3 4 Q [m3/h]
Δp-v-duty curve
2 m
2 m
2 m
2 m
4 m
2 m
4 m3/h
1,1 m
3 m3/h
3,1 m
0,5 m
2 m3/h
2,5 m
0,1 m
1 m3/h
2,1 m
0 m3/h
2,0 m
Δp-c-duty curve
VFD Pump Applications – VFD Pump Applications – Things to ConsiderThings to Consider
• Type of Boiler
• Low mass boilers might not like low flows
•Heat Exchangers Laminar Flows
• Flow Switch Operation
• Paddle type flow switches might not activate
• Requires a change to control (setpoint or differential)
• Pressure
• Temperature
•No change, not a VFD application
•Three Way Valves / Temperature or Pressure?
• Simplicity and Reliability of Equipment
• Flow
• Level
Energy Rebate Template - Custom Template A -- (Tertiary Coil/Unit Pumps)
Before RetrofitThe existing pump _Taco Model CC250C, 5.5, A4B2C1TL, _75_gpm @ _25_’tdh, Supply _var_F, Return _+4_F 4∆T1.0_hp _460_Voltage, _3_Phase, Actual _3.2_ Amp Draw, Average Hours Operation_8760__
After RetrofitNew WILO Stratos Model __2 x 3 – 35 __, _75gpm @ _13_’tdhSupply __var_F, Return _+9__F 9∆T_3/4_hp _230_Voltage, _1_Phase, Actual _0.5_ Amp Draw, Average Hours Operation_8760__ TWO-PHASE KILOWATT (kW) = VOLTS x AMPERES x POWER FACTOR x 2 1000THREE-PHASE KILOWATT (kW) = VOLTS x AMPERES x POWER FACTOR x 1.73 1000 New WILO Pump 0.21kW = 0.5 x 230 x .91 x 20.21 x 24 x 365 x 0.07 = $129.00/yearOld Taco Pump2.32kW = 3.2 x 460 x .91 x 1.732.32 x 24 x 365 x 0.07 = $1,423.00/year Savings Per Year $1,294.00
Boiler Manufacturer _____________________, Model ___________________________BTU Output ________________, Current ∆T Supply F______Return F_________Efficiency at Current ______∆T, and ________Return Water Temperature. After WILO Stratos VFD programming to Design Conditions New Operating ∆T Supply F______Return F_______Boiler Efficiency at Design ∆T __________________ MCF average usage at _____% Boiler Efficiency operation at lower than design ∆T and higher Return Temp.
MCF proposed usage at ____% Boiler Efficiency at Design. All Boiler Manufacturers state their efficiency based upon given ∆T and inlet water temperature, each manufacturer will have many different designs so it is imperitave to get this information from them to deturmine design and current operating conditions. It is not uncommon to find most boilers designed to 20 degree ∆T for 80% efficiency operating at under 10 degree ∆T and 50% or lower efficiency. The WILO Stratos VFD controller built in can correct this deficiency with no external inputs required. This pump utilizes ECM technologies for electrical savings as well as Variable Speed control and management to improve boiler efficiencies as well as pump efficiency.
Evaporator FoulingFouling in the evaporator tubes will also increase energy costs. Fouled evaporator tubes can cause a drop in refrigerant evaporating pressure that reduces its density. As a result, the compressor must pump the gas to a higher pressure to remove an equivalent amount of heat from the chilled water. Again, the compressor must work harder, which increase energy requirements. Fouling of 0.001 Increases Energy Consumption by 10%Based on $0.07 per kWH electricity cost and Power Factor of $ 0.91 on a Efficient Chiller at 40% load = $ 0.25 kW/TonBased on $0.07 per kWH electricity cost and Power Factor of $ 0.91 on a Efficient Chiller at 100% load = $ 0.57 kW/Ton An Example of a 500 Ton Chiller operating at 100% for 2000 hours a season, which if you averaged a seasonal load this is fairly common and fouling often exceeds 0.0042.When making ICE for thermal storage units you can modify the hours and still reach the same costs. Fouling of Reduction in Chiller Efficiency kW/Ton/100% load Wasted Energy/Ton/Season 500 Ton0.0008 9% 0.62 $100.00 $ 50,000.000.0017 18% 0.672 $204.00 $102,000.000.0025 27% 0.724 $308.00 $154,000.000.0033 36% 0.775 $410.00 $205,000.00 Side stream filtration down to 100 micron filtration can save real energy dollars on chiller efficiency. ______________________ Tower Basin & Condenser Tube Cleaning Cost ______________________ Cooling Water Chemical Treatment Cost / Filtering out Solids reduces Bioside Cost by 20% ______________________ Condenser Efficiency x Tonage x kW/Ton x 2000 hours/season (Clean vs. Fouled) ______________________ Make Up Water Savings keeping TSS counts down
One chiller manufacturer states without proper solids filtration efficiency is reduced by 10% in the first 24 hours of operation and continues down for the remainder of the season.