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ASHRAE 90.1, Lowest Energy, First and Life Cost
Future of Pumping
Brazil Visit 2012
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 referencedBlack is the standardRed is the Armstrong solution
Brazil Visit 2012
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
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
“Then the pump impeller shall be trimmed or [max] speed adjusted to meet design flow conditions”
6.7.2.3.3 System Balancing
Brazil Visit 2012
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
Balancing : Industrial Practices
Advantages: -No balancing commissioning required
Disadvantages: 1.Higher pump head required 2.Higher initial valve cost 3.No function at partial load4.Does not meet ASHRAE 90.15.Tendency to clog6.Confusing to install
Dynamic balancing : Flow limiter
7
Brazil Visit 2012
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
Armstrong Solution : manual balancing + variable speed pumping
7℃
12℃
7℃
37℃ 32℃
>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.
9
Brazil Visit 2012
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
• “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
6.7.2.3.3 System Balancing
Brazil Visit 2012
Flow
Head
/Pre
ssur
e
FigureB
Why have Throttling ability in Variable Flow System?
• Ideal is Throttle AVAILABLE if system is outside pump operation
• Reducing speed will not achieve this
• Use on all pumpsSystem Resistance
Speed 1
Speed 2
A
DA = Design PointB = Actual Site Duty Point C = Reduced Speed without
throttlingD = Reduced Speed with
Throttling
BC
Brazil Visit 2012
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
Pumps - Lowest Installed Cost
Brazil Visit 2012
Suction Guide and Flotrex Savings
• 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
Suction guides and Flotrex save components and 30 % in installed costs!
Brazil Visit 2012
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
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
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
Traditional constant speed pump selection
0 0.5 1 1.5 2 2.5 30
20
40
60
80
100
120
10.19
9.30
8.00
30 hp40 hp
Head
(ft
)
Flow (1,000 usgpm)
Series 43008x8x10
BEP
•Selection to left of BEP
•1250gpm at 70ft
•79.1% eff
•27.9 bhp
•40 hp installedSystem curve
5071
83
71
Brazil Visit 2012
Variable Speed Operating Curve – 28ft min press
Feedback sensor
set-point
40
60
80
100
120
Head
(ft
)
0 0.5 1 1.5 2 2.5
Flow (1,000 usgpm)
1848
1760 rpm
528
30 hp
Series 43008x8x10 @ 9.3 in
Operating curve
5068
7580
40 hp
8280
75
68
Minimum Pressure set at 40% design head
System curve
Brazil Visit 2012
Traditional selection at 50% flow
40
60
80
100
120
Head
(ft
)
0 0.5 1 1.5 2 2.5
Flow (1,000 usgpm)
1848 rpm
1240
528
30 hp
Series 43008x8x10 @ 9.3 in
5068
7580
40 hp
8280
75
68
201012
•625gpm at 38.5ft
•67.1%eff
•9.06bhp
Operating curve
System curveSystem curve
Brazil Visit 2012
Traditional Pump Selection Energy Savings
1250gpm at 70ft
Traditional selection (left of BEP):
67.5%ENERGY SAVINGS
Below ASHRAE 90.1 requirements!
79.1% efficiency
27.9 bhp
625gpm at 38.5ft
Operating point at 50% design flow:
67.1% efficiency
9.06 bhp
Brazil Visit 2012
Design Envelope IVS Pump Selection
40
60
80
100
120
Head
(ft
)
0 0.2 0.6 0.8 1 1.6
Flow (1,000 usgpm)
63.0 Hz
40 hp
Series 4300Design Envelope 0611-040.0Integrated Intelligent Variable Speed with Sensorles Control
57 68 7782
8485
84
68
20
•Selection to right of BEP
•1250gpm at 70ft
•68.1% efficiency
•32.5bhp
System curve
58.6 Hz
27.9 Hz
18.0 Hz
8277
140
160
0.4 1.41.2
BEPControl curve
Brazil Visit 2012
Design Envelope IVS Selection at 50% Flow
40
60
80
100
120
Head
(ft
)
0 0.2 0.6 0.8 1 1.6
Flow (1,000 usgpm)
63.0 Hz
40 hp
Series 4300Design Envelope 0611-040.0Integrated Intelligent Variable Speed with Sensorles Control
57 68 7782
8485
84
68
20
•625gpm at 38.5ft
•83.2% efficiency
•7.31bhp
36.9 Hz
20.7 Hz
18.0 Hz
8277
140
160
0.4 1.41.2
Control curve
System curveSystem curve
Brazil Visit 2012
Design Envelope IVS Pump Selection Energy Savings
1250gpm at 70ft
Design Envelope IVS selection:
77.5%ENERGY SAVINGS
Exceeds ASHRAE 90.1 requirements!
68.1% efficiency
32.5bhp
625gpm at 38.5ft
Operating point at 50% design flow:
83.2% efficiency
7.31bhp
Brazil Visit 2012
Design Envelope IVS Selection Software
Brazil Visit 2012
Cross-hairs Pin Envelopes for Design Conditions
Brazil Visit 2012
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
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
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
Brazil Visit 2012
Design Envelope IVS Advantagesvs. Wall Mounted VFD
VS.
Brazil Visit 2012
Design Envelope IVS AdvantagesSelections Save Energy and Cost
Traditional pump with design point to the left of BEP
Design Envelope IVS pump with design point to the right of BEP
Envelope selection often smaller and in a typical example saved 7% in pump cost and 9% in energy costs
Design point 72% 68%
Average load 68% 74%
4” pump 3” pump
Wall-mounted Design Envelope IVS
Brazil Visit 2012
Optimized capacity and motor power
• Impeller trim is optimized to the motor power
• Electronic load limiting
53.5 lps @ 27 m
18.5 kW vs. 22 kW traditional
Savings in smaller motor & controls
Motor/integrated controls = $460 or 9%
Power wiring = $50
Harmonics = 16.6% reduction
A B Design Envelope pump (18.5 kW)
A C Traditional pump (22 kW)
A
C
BEP
B15 kW 18.5 kW
22 kW
30 kW
Brazil Visit 2012
Design Envelope IVS AdvantagesSensorless Savings and Superior Control
• Saving 49% more energy than a sensor in the mechanical room
• Cost savings of $2000 in installation, wiring, and sensor costs
• Simplified commissioning alone is estimated to save $600 per pump
Design Envelope IVS pumps
No pressure sensors necessary
Mechanical room
Brazil Visit 2012
Design Envelope IVS AdvantagesFlow 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
=
Readoutaccuracy+/- 5%
Brazil Visit 2012
Design Envelope IVS advantagesWiring 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
Design Envelope IVS AdvantagesPump 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
Design Envelope IVS AdvantagesMotor Starting Currents
Design Envelope IVS
Brazil Visit 2012
Design Envelope IVS AdvantagesMotor Starters
22kw, 460V starter
Cost Peak Amp Draw(35.1 A)
Demand charge ($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
Design Envelope IVS AdvantagesHarmonic Distortion
• 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
* Some models only
External AC line reactors
5HP
125HP
Brazil Visit 2012
Design Envelope IVS AdvantagesEmission 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
Design Envelope IVS AdvantagesReflected 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
Design Envelope IVS AdvantagesEnvelope Selection Reduces Risk and Cost
Savings on re-selectionsRecent project $25,000 during construction alone
AB
C A – Original design
B – 2nd design
C – Final design
Brazil Visit 2012
Design Envelope IVS AdvantagesEnergy Metering Capability
• Use the Integrated Controls as an energy meter for energy measurement verification
kWh readout
Brazil Visit 2012
Design Envelope IVS – Values & BenefitsWall Space Savings
No room on wall
for multiple VFDs
Brazil Visit 2012
Design Envelope IVS Advantages to 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
9) Envelope selection reduces risk and cost $500
10) Energy metering capability $100
11) Saves Wall space ---
First cost savings
Example: 1000 USgpm at 90 ft Selection: 4300 0611-030.0 Design Envelope IVS
Total $6,240Cost to contractor of IVS pump = $8,350
Only 3) above includes Sensorless control
Savings equal
75% of pump cost
Brazil Visit 2012
Further Design Envelope pumping valuevs. end suction pump
• First cost savings • Pipe savings• Floor Space savings• Maintenance Savings• Savings on reselection
VS.
Brazil Visit 2012
End suction pump installation
• Coupling re-alignment
• Grouting• Inertia pad• Concrete base• Flex connectors
Brazil Visit 2012
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)
Brazil Visit 2012
Design Envelope – values & benefitsFloor space savings
Brazil Visit 2012
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
Brazil Visit 2012
Design Envelope – values & benefitsMaintenance savings (Edmonton Airport)
$8200 annual savings due to faster mechanical seal changes
Brazil Visit 2012
• 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