Slide 1

1 Upon completion of this training one should be able to: Identify different types of hydronic heating systems Identify key components in a simple hydronic heating system Understand the benefits of a variable speed/variable volume hydronic heating system Recognize the retrofit opportunities for converting cs/cv and cs/vv systems to vs/vs systems Learning Outcomes Slide 2 2 Multi-use Facility Slide 3 3 Occupancy 140 persons Building Characteristics Single story 20,000 square feet (250 x 80) Standard construction Slide 4 4 What we will cover: Types of hydronic heating systems Closed loop perimeter heating Closed loop radiant systems Water source heat pumps Ground source heat pumps Piping methods Constant speed/constant volume Constant speed/variable volume Variable speed/variable volume Retrofit market Significant opportunities! Magna3 advantages Slide 5 5 HW Closed Loop Perimeter/ Fan Coil System Optional Variable Speed Components P Sensor Modulating Control Valve (typ.) Secondary Pump Common Pipe 2-way or Two Position Valve (typ.) Boiler Primary Pumps Air Separator Balance Valve (typ.) Boiler Load (typ.) Expansion Tank Slide 6 6 Manual balance valve 3-way control valve 2-way control valve Air separator System piping components Slide 7 7 Fan coil VAV box Slide 8 8 HW Closed Loop Radiant Floor/Snow Melt System Radiant Floor or Snow Melt Panels Boiler #2Boiler #1 P1 P2 Secondary Pump Mixing Valve Primary Pumps P1 & P2* Redundant* Expansion Tank Common Pipe Air Separator Slide 9 9 HW Closed Loop Radiant Floor/Snow Melt System Slide 10 10 HW Closed Loop Radiant Floor/Snow Melt System Slide 11 11 Heat Pumps 60F HPWS 53F HPWR Heat Pump 160F HHWR 180F HHWS 53F CHWR Fan Coil Unit 45F CHWS Air 60F HPWS 67F HPWR 60F HPWR 60F HPWS Heat Pump Cooling Heating Slide 12 12 Heat Pump Operation 53F HPWR Fan Air 60F HPWS Heating Water to Refrigerant Heat Exchanger Compressor Reversing Valve Refrigerant Coil Expansion Valve Refrigerant Piping Slide 13 13 Heat Pumps Types: Water source Boiler and chiller Ground source Bore field / pond loop / well Hybrid A ground source plus supplemental heating or cooling Slide 14 14 Closed Circuit Cooling Tower WSHP Buffer Tank ( Optional )) Compression Tank Water Source Heat Pump (WSHP) Boiler WSHP Make-up Water Primary Pumps P1 & P2* Redundant* Air Separator Slide 15 15 WSHP Components Cooling Towers Boilers Slide 16 16 Ground Source Heat Pump (GSHP) Bore Field GSHP Buffer Tank ( Optional ) Compression Tank GSHP Make-up Water HP Loop Pumps P1 & P2* Redundant* Air Separator Bore Field Loop Pump Slide 17 17 GSHP Slide 18 18 Hybrid Ground Source Heat Pump Bore Field GSHP Buffer Tank ( Optional ) Compression Tank GSHP Make-up Water HP Loop Pumps P1 & P2* Redundant* Air Separator Bore Field Loop Pump Slide 19 19 Hydronic Piping Systems Slide 20 20 Hydronic Piping Systems Types: Constant Speed/Constant Volume (CS/CV) Piping & equipment requirements Deficiencies Energy usage Constant Speed/Variable Volume (CS/VV) Piping & equipment requirements Advantages Energy usage Variable Speed/Variable Volume (VS/VV) Piping & equipment requirements Advantages Energy usage Slide 21 21 CS/CV Piping System 3-way Valve Load Balance Valve (Typ.) Expansion Tank Boiler 2* Boiler 1 Primary Pumps P1 & P2* * Redundant Air Separator Slide 22 22 CS/CV System Deficiencies High return water temperatures Robs hot water from other coils at part loaded conditions Increases flow Adds additional boilers on line Boiler performance is reduced Slide 23 23 CS/CV System Load for Multi-use Facility: Chicago, IL Plot load profile Select pump for 108 gpm @ 36 ft Cooling Profile Heating Profile Slide 24 24 40 35 30 25 20 15 10 5 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 Flow (gpm) Head (ft) 108 gpm @ 36 ft 97% CS/CV Pump Slide 25 25 Pump Energy Consumption - CS/CV CS/CV Slide 26 26 CS/VV HW Piping Systems Primary Pumps P1 & P2* *Redundant Return Supply Secondary Pumps P1 & P2* Boiler 1 Boiler 2* Expansion Tank Air Separator Slide 27 27 CS/VV Pumping Systems Add secondary pumps Add common pipe Add system bypass Add 2-way valves Eliminate 3-way valvesor Slide 28 28 CS/VV Pumping Systems Eliminate 3-way valves Disable 3-way valves Shut bypass valve Disconnect bypass pipe Actuator may be undersized for 2-way operation Does this make $ense? Slide 29 29 40 35 30 25 20 15 10 5 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 Flow (gpm) Head (ft) 108 gpm @ 36 ft 97% CS/VV Pump Curve Slide 30 30 CS/VV Advantages Lower return water temperatures Minimizes flow to coils Decreases secondary flow Reduces boilers on line Boiler performance is increased Ease of system operation Energy savings Preferred piping method Slide 31 31 Pump Energy Consumption - CS/VV CS/CV CS/VV Slide 32 32 VS/VV Pumping Add: Variable frequency drive (VFD) Programmable logic controller (PLC) Differential pressure sensors (P) Direct digital controls (DDC) Save 75% AOC versus CS/CV! Slide 33 33 VS/VV Hot Water Systems Secondary Pumps VSP1 & VSP2* P Sensor *Redundant Return Supply Boiler 1 Boiler 2* VS Pumps And Controls Expansion Tank Air Separator Slide 34 34 Pump Curve Summary CS/CV 108 gpm @ 36 ft CS/VV 108 gpm @ 36 ft 54 gpm @ 37 ft 108 gpm @ 36 ft VS/VV 54 gpm @ 9 ft Slide 35 35 VS/VV Pump Curve 108 gpm @ 36 ft Flow (gpm) Head (ft) 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 40 35 30 25 20 15 10 5 0 Magna3 100-120 Slide 36 36 VS/VV Advantages Optimizes return water temperatures Optimizes flow to coils Decreases secondary flow Reduces boilers on line Boiler performance is increased Ease of system operation Optimum energy savings Slide 37 37 Pump Energy Consumption - VS/VV CS/CV CS/VV VS/VV Slide 38 38 VS/VV Advantages Cost effective design Primary-secondary vs pumping Proper common pipe design 2-way valve operation Save up to 50% of pumping energy over CS/VV systems Save up to 75% of pumping energy over CS/CV systems Slide 39 39 Additional System Savings Additional sources of energy savings Boiler operation T optimization Sources of first cost savings Pump sizing Boiler sizing Valve sizing Pipe sizing Slide 40 40 VS/VV Pumping Add: Variable frequency drive (VFD) Programmable logic controller (PLC) Differential pressure sensors (P) Direct digital controls (DDC) Or add Slide 41 41 Demand More Magna3! Slide 42 42 HW Systems w/ Magna3 Secondary Pumps VSP1 & VSP2 Primary Pumps MP1 & MP2* *Redundant Return Supply Boiler 1 Boiler 2* Magna3 VS Pumps With Controls Expansion Tank Air Separator Slide 43 43 VS/VV Retrofit Opportunities Converting CS/CV to VS/VV Steam systems 3-pipe hot/chilled water systems One pipe hot water systems 3-way valve hot water systems Uncontrolled radiant systems Over-sized boiler pumps Slide 44 44 VS/VV Retrofit Opportunities Converting CS/VV to VS/VV CS 2-way valve HW systems CS three pipe systems Systems with poor T control Systems with over-sized pumps Systems with local P sensors Systems with single VS pumps Slide 45 45 Demand More Magna3 - Features & Benefits Slide 46 46 MAGNA3 RANGE RELIABILITY INTELLIGENCE EFFICIENCY Slide 47 47 Range 1. What is the range of our current Magna? Number of pumps Voltage Flow & Head Temperature Applications 2. What is the range of MAGNA3? Number of pumps Voltage Flow & Head Temperature Applications Slide 48 48 Range 14 Hydraulic models (11 Single, 3 Twin) Total 37 pumps 115V up to 1HP 208-230V all 14 F to 230 F Cast Iron and Stainless Water & water/glycol up to 50% Heating, DHW, Solar, Cooling & Geothermal Slide 49 49 Reliability How long has Grundfos manufactured and sold circulators? How many Alphas/Magnas installed? What is the percentage warranty rate on Magna? Why are they so reliable? When was the project for Magna3 started? How many hours have the Magna3 been tested? Slide 50 50 Intelligent Control Separating Magna3 from the rest of the pack Control Options Slide 51 51 H(ft) P (W) Q (GPM) Intelligent Control Constant Curve Slide 52 52 H(ft) P (W) Q (GPM) Intelligent Control - Constant Curve Slide 53 53 H(ft) P (W) Q (GPM) Intelligent Control - Constant Pressure Slide 54 54 H(ft) P (W) Q (GPM) Intelligent Control - Proportional Pressure 50 % H Set H Set Slide 55 55 What is Slide 56 56 H(ft) P (W) Q (GPM) Intelligent Control - AUTO ADAPT 5 Feet 50 % H MaxH Max Slide 57 57 H(ft) P (W) Q (GPM) Intelligent Control - AUTO ADAPT 5 Feet Old AUTO ADAPT Set Point New AUTO ADAPT Set Point Slide 58 58 Intelligent Control Flow ADAPT / Flow LIMIT Flow Limit 0255075100 FLOW LIMIT Potential saving compared to an unintelligent pump Potential saving compared to proportional pressure mode Duty point Additional saving with FLOW LIMIT Performance curve Slide 59 59 Intelligent Control - CONSTANT TEMPERATURE H(ft) Q (GPM) Slide 60 60 Intelligent Control - DIFFERENTIAL TEMPERATURE H(ft) Q (GPM) Slide 61 61 Intelligent Monitoring & Sensing Temperature Speed Flow Power Head Energy BTU History Slide 62 62 Intelligent Monitoring & Sensing Operating Mode Setpoint Control Mode Alarm/Warning Power and Energy Pressure Head Flow Speed and Frequency Digital Input/Output Motor Current Liquid Temperature Operating Hours Total On Time Number of Starts Return Temperature BTU BTU/hr Differential Temperature and more.. CIM Accessory delivers all of this data from the pump to the BMS System Bacnet Lonworks Modbus Profibus SAVES $$$ by eliminating the need for additional monitoring equipment and data point integration in the system Slide 63 63 Intelligent Interface Slide 64 64 Intelligent Interface - Startup Slide 65 65 Intelligent Interface Menu Tabs Slide 66 66 Intelligent Interface Monitoring MAGNA3 comes with a monitoring function, which makes it possible to keep track of the heat energy distribution and consumption within a system. This avoids excessive energy bills caused by system imbalances. The heat energy meter has an accuracy between +/-1% and +/-10% and makes installing a separate energy metering device within your system superfluous. Temperature input from return pipe Slide 67 67 Intelligent Interface Work Log Every duty point and the operational conditions are tracked and stored in the pump. The 3D work log and duty over time curve, provide instant overviews of historical pump performance and operational conditions. The perfect tools for pump optimization, replacement and troubleshooting. Slide 68 68 Efficiency Integrated Grundfos Sensor, Diff. Press & Temperature Optimized 3D Hydraulic Design Permanent Magnet Rotor Stronger Magnets Composite Rotor Can reduced magnetic losses Compact Stator reduces copper and resistance losses Insulation Shell reduces heat loss through pump housing Intelligent control sizes pump for demand Slide 69 69 EEI What is EEI (Energy Efficiency Index)? When was it adopted? What is its future? What does it mean to us (USA)? Slide 70 70 Load Profiles Flow % Time % 44% 15% 35% 6% 100%75%50% 25% 10 20 30 40 50 60 70 80 90 100 Slide 71 71 Why VFDs? What percent of the operating time is the demand on a heating system A)100%? B)75%? C)50%? D)25%? Why are VFDs used? Slide 72 72 Load Profile for EEI Flow % Time % 44% 15% 35% 6% 100%75%50% 25% P avg EEI = --------- x C 20% P ref Slide 73 73 P ref for EEI P avg EEI = --------- x C 20% P ref Slide 74 74 Flow % Head 100% 75%50%25% T, 44%T, 35%T, 15%T, 6% Constant Curve Prop. Press. Curve P avg for EEI H P hyd Ma x 0.5 x H P hyd Max P avg EEI = --------- x C 20% P ref Slide 75 75 Energy Efficiency Index is a much better measure of energy usage than BEP EEI 0.27 EEI 0.23 EEI 0.20 EEI 0.17 MAGNA3 65-120 75% Energy Reduction without AUTO ADAPT