Leed Buildings & Smart Pumps - ashraemontreal.orgashraemontreal.org/ashrae/data/files/pdf/...Leed...

Leed Buildings &

Smart Pumps

The next generation of centrifugal pumps with integrated intelligence & connectivity

Marcelo Acosta P.Eng., PMP, Leed AP

Armstrong Fluid [email protected]

ASHRAE Technical Committees

In ASHRAE there are:• 96 Technical Committees• 54 Standard Project Committees• 21 Standing Standard Project Committees (90.1, 62.1)• 17 Guideline Project Committees• 7 Multidisciplinary Task Groups (BIM, Occupant Behaviour)• 2 Technical Research Groups (Cold Climate Blg Design)• 1 Task Group (HVAC Security)

TOTAL: 198 Workgroups (Many with subgroups and RP’s)

ASHRAE TC 1.4 – Controls Fundamentals and Applications

Spun off:• TC 7.5 – Smart Building Systems (mostly academic Research Projects)• SGPC 13 – Specifying Building Automation Systems• GPC 36 – High Performance Sequence of Operation for HVAC Systems• SSPC 135 – BACnet

Also works closely with:• SSPC 189.1 – Design of High Performance Green Buildings• 62.1 – Ventilation for Acceptable Indoor Air Quality• 90.1 – Energy Efficient Design of New Buildings• And several others (labs, renewables, energy storage…)

Controls is the way to achieve the increase in energy performance needed in the 21st century

Learning Objectives

After this session you should be able to:

• Identify Smart Pumps• List the benefits of using Smart Pumps• Select Smart Pumps to optimize energy efficiency• Estimate savings from using Smart Pumps• Understand the purpose of Smart Pumps features• Decide which Smart Pumps features should be used for a

project and which ones shouldn’t• Understand what info is needed to specify Smart Pumps

Session Content

• Pumps fundamentals (20 min)• Smart Pumps (35 min)

• Definition (5 min)• Minimum Features (10 min)• Common Features (10 min)• Advanced Features (5 min)• Future Features (5 min)

• Q&A (5 min)

Pumping Energy Consumption

Source: DOE Office of Industrial Technology

Pump Life Cycle Costs

Nearly 80% life cycle cost after first year

“…pumping systems account for nearly 20 percent of the world’s electrical energy demand…”

Pump Life Cycle Costs ‐ Hydraulic Institute & Europump

Source: Hydraulic Institute and Pump Systems Matter

Savings Potential

Source: Department of Energy – Office of Industrial Technology

Pumping systems have the highest potential for energy saving efforts

Compressed air systems27.0%

Fans10.0%

Pumps50.5%

Other12.5%

Water has approximately 3500 times the heat transport capacity of air

Water can transport heat using less than 5% or energy than fans

Pumping – Energy Savings Potential

US Energy Consumption 2010

Buildings40%

Transportation 28%

Industry32%

Total Commercial US Energy

HVAC17%

Other Identifiable

13%

Non‐Identifiable

10%

US Building Energy

Source: US Department of Energy – Buildings Data Energy Handbook

24.8% is pumps

20% is determined by pumps

Pump Fundamentals - Types

Human powered Gravity powered

Commercial Buildings

Building HVAC

Variable Speed

Potable water

Constant Speed

Fire

Condenser

SewerSubmersible

Industrial

Machines that move fluids

Pump Fundamentals

Pump at constant speed. Valve opens/closes Pump curve

Valve at fixed position. Pump speeds up/down System curve

Operation point can move over a ‘map’

PressBoost (H)

Flow (Q)

60Hz

20

30

40

50

Valve full openMinimum hydraulic resistance

Applies to fans too

Power Delivered to the Fluid Valve at fixed position: Flow proportional to SpeedPress proportional to Speed2

Power proportional to Speed3

Pump, motor & drive efficiencyInput Power =

Reducing the Energy Consumed requires 3 types of “Smarts”

1. Smart design and manufacturing to create efficient and high performing equipment

2. Smart selection of the right equipment for the application

3. Smart controls to operate the equipment efficiently

Choke zone

Pump FundamentalsHVAC Applications

Condenser

Condenser

Condenser

Primary

Primary

Primary

Secondary

Primary

PrimaryPrimary

Primary

Primary

Chiller plant

Boiler plant

Condenser

Primary

Pump FundamentalsHVAC Applications

Primary

Geo field

Each load requires a certain amount of flow current system flowdemandTitle 24 / ASHRAE 90.1 :Pump speed adjusteddown (making valves open) until the most open valve isclose to 100% open.Most efficient pump/fan control method, butRequires stable load demand and stablevalves/dampers

Pump FundamentalsControl Method Impact

Press Boost

Flow

Max Flow, Max Press

All valvesopen

Constant Speed

Constant Head

Power Delivered

Power Wasted!

Distribution Pump (or Fan)

Title 2490.1

Friction Losses

Trace

• Step 1 – Determine the Control Method• Step 2 – Calculate the Power Delivered at each flow: Flow x Diff Press

• Step 3 – Use the flow profile to determine the pump Energy Output profile:Pwr x hrs

• Step 4 – Determine the pump/fan Efficiency at each flow for the control method

• Step 5 – Calculate the Energy Input profile (Energy output / Eff) and integrate

Pump FundamentalsAnnual Energy Use Estimation Title 24

90.1

Power Output

Energy output

Energy input

Efficiency

%time

Combined drive, motor & pump efficiency

• If we have to select a pump in a group, the one which will use minimum energy input, maximizes the correlation between Efficiency and Energy output

• This happens for the pump which has its best efficiency curve closest to the Energy output “center of mass”

• The information usually available is the efficiency curves and values

• The pump/fan has to be able to provide the design day flow and diff pressure

Pump FundamentalsBest Energy Efficiency Selection

Energy output

Smart selection of the right equipment for the application

Efficiency

77

80

7569

• Pumps/fans with high best efficiency but rapidly declining don’t perform well

• Motor and drive efficiency decrease with power

• In summary:


60

7572

Efficiency

80

Efficiency

Energy inputEnergy input

7470

73657365

73

60

55

Choose a pump/fan whose best efficiency curve is close to the energy output profile center of mass, with high best efficiency but also slow declining, and with the smallest motor and drive that still meet the design point

Energy output

Power

40%

100 95

Percent of Rated Full Power (HP)

• The determination of the output energy “center of mass” depends heavily on the flow profile

• The flow profile depends on:


Energy output

Energy transferred

Coil Flow

50%

10% 30% 40%

1. The type of building (school, residential, hospital, data center, mixed…), which determine the occupancy patterns and use. I.e. internal loads profile

2. The location (weather) and building insulation. I.e. external load profile

3. The presence of heat recovery and free air cooling4. The pump application (primary, secondary,

condenser)5. The fluid type and temperature control method

% of 1000 hrs % of 8760 hrs

Flow FlowCondo Bldg., Vancouver, BC Data Center, Miami, FL

If all that info is not available, then use the following “center of mass”, relative to the design day flow and head:

Flow Head• Secondary pumps 0.5 0.65• Primary pumps in VP/VS 1 1• Distribution primary pumps 0.5 0.4• VS condenser pumps 0.7 0.5

• CS condenser pumps should be designed for 12 to 14°F design day T(see “Optimizing Design &Control of Chilled Water Plants Part 4 Chiller & Cooling Tower Selection”, ASHRAE Journal, Mar 2012)

Pump FundamentalsBest Energy Efficiency Selection – Rules of thumb

Constant Speed Pump Variable Speed Pump Smart Pump

Initial Cost $150,000 $200,000 $215,000

Installation Cost $34,500 $47,000 $37,000

Annual KwhR (Reactive) 140,515 58,789 58,789

Total Energy Cost (P.V.) $174,961 $73,200 $53,200

Operating Cost (P.V.) $451,300 $338,475 $305,116

Repair/Maint. Cost (P.V.) $56,412 $66,715 $45,652

Downtime Cost (P.V.) $112,825 $98,615 $56,000

Enviromental Cost (P.V.) $5,614 $5,614 $5,614

Disposal Cost (P.V.) $232 $232 $232

Scrap Value (P.V.) ($673) ($673) ($673)

Depreciation (P.V.) ($45,168) ($52,251) ($52,251)

Present Value of Cost $940,003 $776,927 $664,890

Life cycle costsEnergy is only part of the story

‐ 20 year life cycle‐ Annual Discount Rate 6%‐ Customer Tax Rate 31%‐ Straight Line Depreciation Over

7 Years

‐ $0.1 per kWh‐ Energy cost increases

5%/year‐ Non‐energy inflation 4%

• Pump map• Pump applications• Control methods• Annual energy use estimation• Pump selection for lowest energy use• Pump selection thumb rules• Life cycle costs

RecapWe’ve seen so far

Smart Pumps

Flexible Adapts to changing situations Multiple modes of operationField configurableProtect itself from hazards

KnowledgeableIs aware of the situationHas relevant knowledge and uses it

Sensorless dataSpecific diagnosticsUses this info for control

Articulate Clearly explains the situation Asks for help when needed

Multiple communication methodsSpecific data pointsWarnings and Alarms

Smart PumpsWhat is a Smart Pump?

Smart means…

• Smarts do not replace physical capabilities: they make the best use of them• Smarts do not replace proper design and selection for the application

Geoffrey MutaiKenya

Fastest marathonist

Usain BoltJamaica

Fastest man on 100m

Stephen HawkingEngland

Smartest physist

SmartsLimitations

Sensorless readings Operation point: Flow and Head

Multiple modes of operationStand alone control using Sensorless dataStand alone control from sensorsFollow external commands

Protect itself from hazards Overload protection

Field configurableOperation ModeSetpointsInputs configuration

Smart PumpsMinimum features

Sensorless ReadingsH

PWR Q

60Hz

20

30

40

50

60Hz

20

30

40

50

Power – Speed (Hz)Curves

P1

H1

Q1

(P1, S1)S1

(Q1, H1)

Head – Flow Map

• Each (Power, Speed) point determines a specific Pressure and Flow…

• …for certain pumps

• Smart Pumps store a table of (Power, Speed, Head, Flow) points

• Interpolation is done using affinity rules

Sensorless ReadingsH

PWR Q

60Hz

20

30

40

50

60Hz

20

30

40

50

P1

S1

• 5% accuracy inside the Design Envelope, 10% outside

• Suitable for cost allocation but not for submetering

• At some flow the power curvesreach a maximum: Can’t tell on which side of the maximum is operating

• Low power curves slope reduces accuracy

• Low power reduces power readings resolution: reduced accuracy

• Fluid density (glycol, water, mix) changes power draw

• Temperature changes fluid viscosity and density: reduced accuracy if not compensated

• Motor winding temp changes slip in induction motors

• Unsuitable for manometricpressure, (booster) unless suction pressure is constant

• Impeller wear over time. It can be recalibrated.

Limitations

Quadratic Control (Flow Loss Compensation)

Press Boost(H)

Flow (Q)

Friction Losses

Remote Differential Pressure Setpoint

• Adjusting the speed to maintain the operation point over the control curve mimics control from a remote sensor

• The pumps flow and pressure boost need to be known

• This can be achieved with sensors…

• Or with Sensorless values

Sensorless controlH

P Q

60Hz

20

30

40

50

60Hz

20

30

40

50

53

53

Power – Speed (Hz)Curve

1) Operating points on the control curve can be translated into a power‐speed relationship

2) As a control valve closes the operating point starts to move up the pump curve

3) The controller recognises this as a reduction in power at the current operating speed

4) The controller calculates a new operating speed to get back on the power – speed curve and hence the pumps control curve

5) The speed is reduced to revert operation to the control curve

6) The reverse happens when the control valve opens

7) When control curve set‐points are adjusted the controller automatically recalculates the power – speed curve

Sensorless Control

Press Boost(H)

Flow (Q)

Friction Losses

Remote Differential Pressure Setpoint

• Changing the control curve to a parallel curve, up or down…• …is equivalent to changing the remote sensor setpoint• This changes the pressure boost by the same amount at all flows

Changing the Control Curve

Friction Losses

• Changing the control curve to a non‐parallel curve…• …is equivalent to changing the remote sensor location• This allows adjusting to “unevenness” with less energy waste, when the valves positions is unknown

Sensorless Control

• Zones with very different flow requirements (“high unevenness”)

• Can do, but without valve position based reset, the energy savings are limited

• Multiple sensors is a better solution• Low Remote Setpoint relative to Design Head

• Valve based reset has to change the “remote setpoint”

• Frequent, abrupt changes in flow demand, as in industrial applications

• Stability vs. reactivity• Unsuitable for domestic booster applications (manometric pressure)

Limitations

Fuzzy intersection:Unstable operation

• Can’t maintain a fixed pressure at a location past the first branching…

• …but that’s not the goal: it’s ensuring loads are satisfied with minimal energy use

• Less sensitive to highly uneven demand from zones: • Sensor works well only if it is in the most demanding branch all the time

• With 40% of design head at zero flow, Sensorless works well as long as the highest demand is less than 60% above average (for cooling) and 40% above average (for heating)

• Easy to reconfigure for site conditions and system modifications

Satisfying LoadsSensorless Control vs. Remote Sensor

Unrealistictopology

Central Plant

No Demand

Unsatisfied

Sensorless Control vs. Remote Sensor

• More flexible: can change “remote location”, not only remote setpoint

• Can be combined with sensors on critical loads• Less sensitive to missing/incorrect balancing • Ready to go from day 1

• No waiting for sensor and controls being ready• Flow reading readily available for balancing and fine tuning, makes it more likely to happen

• Motor sized for design point and not for max power @ full speed (3% yearly energy savings and lower first cost)

• Drive parameters fine tuned for the motor and pump application (2%)

Energy Use

Smart Pumps

Constant Speed Distribution Pump Variable speed, remote sensor Smart Pump

100 40 30

Energy Savings

Relative to drive on the wall + remote sensor control:

% SavingsSelection for best efficiency over energy output profile 15 to 20Sensorless + site tuning 5Impeller trim and Motor sized for design conditions 3Drive fine tuned for the application 2Less time at fixed speed (ready out of the box + diagnostics) 2

Smart Pumps

1. Control based on flow demand2. Power use at 50% flow

1. Usually power at 50% flow is 23% of Design Point power 23% better than the 30% required

3. Sensorless Control parameters can be adjusted based on valve position to change the “remote pressure setpoint”

4. Meets the required Design Point efficiency with “flat efficiency curves”5. In a Feb 2016 interpretation, the 90.1 committee confirmed Sensorless

Control complies with 90.1 section 6.5.4.2 Hydronic Variable Flow Systems

Compliance with 90.1 & Title 24

Smart Pumps

• Very difficult to get points directly just from equipment selection

• Smart pumps contribute towards1. Innovation points – The equipment and the new system controls

strategies possible2. Energy savings points – Of the pumps and the system they are in3. Commissioning process points – Simplified process, extensive report,

automated ongoing self‐tuning

Leed points

Smart Pumps

1. Lower installation and commissioning costs

2. Operational costs – Less tweaking, less major repairs, less downtime

3. Availability – Higher %time, earlier4. Risk – Adapts to changes, higher control

of maintenance downtime5. Visibility – More detailed information,

easier tuning and troubleshooting6. Simplicity – Less components7. Redundancy

Other benefits

Energy Performance & Compliance

Installed Cost

Design Simplification

Maintenance & Reliability

Risk

Space

VS.

Smart PumpsRedundancy

Press Boost(H)

Flow (Q)50% 80%85%

100%80% Flow 85% Flow

45°F 85 87

42°F 95 97

41°F 98 100

40°F 101 103

39°F 104 107

Percent of Design Point heat

The redundant pump may not be needed at all !!

Smart PumpsCommonly Found Features

Multiple communication methodsHardwiredSerial: BACnet, Modbus

Pump Alarms & Warnings

Airlock/Broken coupling Excessive demand (broken pipe)Choke (EOC)Deadhead Locked rotor

Specific data pointsFlow, Head, kWhControl Method parametersPump Alarms and Warnings

Parallel OperationStarting/Stopping pumps in a set to satisfy demand

Smart Pumps

Optimized Parallel OperationUse Sensorless maps to find the best pump combination

Self-tuningAdjust control curve based on observed flow demand and system hydraulic resistance

Data processingFlow and kW profilesBTU (with temp sensors), totalization and profileWire-to-Water efficiency

Permanent magnet motorsHigher efficiencyPrecise speed control

Wireless communication Bluetooth with companion Apps

Real Time Functions

ScheduleAnnual holidaysDaylight savingsTime Stamped data logs and alarms

Advanced Features (Unusual)

Smart Pumps

Optionalsoftware upgrades

Min Flow (by-pass valve & speed increase)Max Flow (speed reduction)Optimized Parallel OperationSatisfy multiple sensor zones & SensorlessOngoing self-tuningSeasonal setpoints

Internet of Things

Upload data for remote processing and storageCustom distribution of notificationsAutomatic software upgrades

Wi-FiWebserver advanced user interfaceRemote access

Improved Sensorless accuracy

Suitable for submetering

Advanced Features (Since 2017)

0%

100%

20%

40%

60%

80%

FLOW

HEA

D

EFFICIEN

CY

POWER

1P EFFY 2P EFFY 3P EFFY

0%

100%

20%

40%

60%

80%

FLOW

HEA

D

EFFICIEN

CY

POWER


BESTEFFICIENCYSTAGING

SPEED BASEDSTAGING

Parallel Sensorless Staging


SPEED BASED STAGING

Energy Savings:3 x 40HP Pumps

Operating Cost* – Speed Based Staging~ $30,371

Best Efficiency Staging~ $20,092

34% Saving vs. Speed Sequencing

*Based on $0.10/kWh – 12 months operation – 40% design head min pressure

= Areas of highest inefficiency

An integrated approach to reducing system costParallel Sensorless Pump Control – Performance Benefits

20% Saving vs. Single Pump

Single Pump

Smart PumpsFuture Features (Soon to come)

Diagnostics on device

Vibration analysis: bearing, misalignment, motor winding short circuitService required alerts based on estimated wearDefective motor winding insulation detection

Clouddiagnostics

Using processor intensive algorithmsComparison of all similar pumps in the fieldService history & parts traceability

Expanded WiFiWireless coordination of multi-pump applicationMesh network

Boiler plant example

2 x 2500 Mbtu/hrWater Tube Condensing Efficiency > 86%20°F (11°C) TFlow turndown 2:1Flame turndown 5:1

2 x 3HPConstant Speed

2 x 6HPVariable Speed

• 2 x 100% boilers, constant primary / variable secondary

• Boilers with factory installed controls

• Temp reset 140°F‐170°F (60°C – 77°C)

• Primary pumps start with associated boiler

• Secondary pumps controlled as per ASHRAE 90.1 ‐ 6.5.4.2

• How can we improve energy efficiency?

Boiler plant example – First Idea

• Replace with high efficiency constant speed pumps (better hydraulics, ECM motors)

Original High Eff. CS

Installed $ 6,000 12,000

W/W eff % 0.55 0.75

Energy use $ 985 $ 722

Energysavings ‐‐ 27 %

Annual Savings ‐‐ $ 262

Simplepayback years

‐‐ 22.8

Original High Eff. CS Ideal CS

Installed $ 6,000 12,000 12,000

W/W eff % 0.55 0.75 1

Energy use $ 985 $ 722 $541

Energysavings ‐‐ 27 % 45%

Annual Savings ‐‐ $ 262 $443

Simplepayback years

‐‐ 22.8 13.5

Boiler plant example – Another Idea

• Use variable speed pumps of the same efficiency as the originals

• Control with flow switches on bypass• When the low flow switch closes, the pumps slow down

• When the very low flow switch opens, the pumps speed up

• Pumps minimum speed ensures flow is above the boilers minimum flow

• This maintains primary flow slightly above the secondary flow, at a relative low cost

• Doesn’t require any additional controls; just the drives

Very low flow switch

Low flow switch

Boiler plant example – Using Controls to Improve Efficiency

Original Ideal CS VS Controls

Installed $ 6,000 12,000 12,000

W/W eff % 0.55 1 0.52

Energy use $ 985 $ 541 $ 492

Energysavings ‐‐ 45 % 49 %

Annual Savings ‐‐ $ 443 $ 490

Simplepayback years ‐‐ 13.5 12.2

Original Ideal CS VS Controls

Installed $ 6,000 12,000 12,000

W/W eff % 0.55 1 0.52

Energy use $ 985 $ 541 $ 492

Boilers Energy $39,254 $39,254 $ 36,899

Energysavings ‐‐ 45 % 1,724 %

Annual Savings ‐‐ $ 443 $ 2,848


And the pumps’ life expectancy is extended!

Boiler plant example – 21st Century Controls

• 21st century twist: replace with Smart Pumps (IoT, on‐board diagnostics, preprogramed)

Original Controls Smart Pumps

Installed $ 6,000 12,000 11,500

W/W eff % 0.55 0.54 0.71

Energysavings ‐‐ 1,724 % 1,740 %


• Diagnostics report if system doesn’t operate as intended (overrides, sensor/pump failures)

• Setup can be just a pull‐down menu • Collected data proves savings and can quantify cost of incorrect operation

• Smart Pump definition• Minimum features• Sensorless readings & limits• Sensorless Control…• …vs. DP Sensor • Compliance with standards• Other benefits• Parallel Sensorless• Common, Advanced and Future features

RecapWe’ve seen so far

Takeaways

• Smart equipment are not traditional equipment with some embedded controls

• They are designed for variable speed and part load performance and

• Should be selected with that in mind

• They can efficiently adapt to different systems and situations, within certain limits

• They provide tools to keep systems fine tuned and minimize expensive repairs

• Education of designers, builders and operations & maintenance staff is essential to achieve the savings

Smart Pumps

Marcelo Acosta P.Eng., PMP, Leed AP

Armstrong Fluid [email protected]

Leed Buildings & Smart Pumps - ashraemontreal.orgashraemontreal.org/ashrae/data/files/pdf/...Leed...

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