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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

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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

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Design Envelope IVS AdvantagesEnergy Metering Capability

• Use the Integrated Controls as an energy meter for energy measurement verification

kWh readout

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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.

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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