Distributed Pumping Concept

How to achieve more energy efficiency

from your chilled water system?

Presented by Supriyadi PT. Grundfos Pompa

Chilled Water Distributed Pumps

MAGNA3 TPE3

PERFORMANCE RANGE

MAGNA3

Distributed Pumping Concept Improve performance by mean : In balancing In operation cost In Flexibility In Comfort In Reliability

The cost of running pumps

Initial capital and life time maintenance costs of a pump account for only 5% of the total life cycle cost

Other 95% = running energy costs

5%

95%

Pumps For HVAC Applications

The Centrifugal Pump

Provides the primary force to distribute and recirculate hot and chilled water in a centralized system

Most important component in any hydronic system

Regulates pressure and temperature of the chilled water system

Proper pump selection minimizes energy use, ensure proper distribution and optimizes heat transfer

How do we size a chilled water pump?

Flow + Head = Pump

Calculating Pump Head Losses


Hydraulic Gradient

Reducing Pump Head Losses


Hydraulic Gradient

Chilled Water System- Water Cooled

High Energy Consumption !

Primary Pumping Design

Return

C H I L L E R

C H I L L E R

C H I L L E R

Supply

Pump Controller

Adjustable Freqy. Drives

Variable vs Constant Head Loss


SECONDARY

PUMP PRIMARY

PUMP

VFD

Pump Energy Saving Basic ! ~ with VFD Secondary Pump

Primary & secondary Pumping Design

Any Other Method To Further

Save Pump Energy ???

Return

C H I L L E R

C H I L L E R

C H I L L E R

Supply

Pump Controller

Adjustable Freqy. Drives

Variable vs Constant Head Loss

Conventional Primary Direct Pumping System

Variable Speed Primary Pump

Chiller

M

M

M

M

M

M

VSD

DPT

Distributed Pumping Concept A No-Brake Solution

Primary Pump

Chiller

VSD

VSD

VSD

VSD

VSD

VSD

Why would YOU need distributed pumping?

1. Energy Savings

2. Balancing the water distribution

3. Reduce commissioning time and cost

4. Eliminate low T syndrome

1) Design high T Chilled water System Btu= 500xQxT increase T, reduce Q

BHp=QxH/(3960x%) reduce Q, reduce pump BHp

Increase T with 6F, BHp reduce 37.5% !!!

T = 10F

12000Btu=500xQx10

Q=2.4 usgpm

T = 16F

12000Btu=500xQx16

Q=1.5 usgpm

Similar Cooling Capacity

Energy Efficient Distribution


2) Select Low P AHU

BHp=QxH/(3960x%) low P=low H, reduce pump BHp

Similar Cooling Capacity

Cooling Coil :

4 row/ 14 fin/ half circuit

Pressure Drop: 33.4ft

Cooling Coil :

6 row/ 11 fin/ full circuit

Pressure Drop: 4.9ft


3) Using VFD Pump For AHU To Replace

Modulating Valve Modulating valve 1~2 time P of AHU, using VFD

pump can eliminate valve P. Reduce pump BHp

Cooling Coil Pd 20ft

Modulating valve Pd 20~40ft

Total Pd = 40~60ft !!

VFD Pump does not have

pressure drop, in fact

generates positive pressure.

Total Pd = FCU Pd = 20ft

Comparing Energy Efficiency Calculating Pump Power Consumption

P = . . .

3600 .

where P is the power input to shaft, watts Q is the flow rate, m3/h H is the head, m g is acceleration of gravity, m/s2 is density of water, kg/m3 is efficiency of the pump, %

Conventional Primary Direct Pumping System Pumping Energy

Variable Speed Primary Pump

Chiller

M

M

M

M

M

P 3m P 4m

P 3m

P 3m

P 3m

P 3m

P 4m

P 4m

P 4m

P 4m

P 2m

P 2m

P 2m

P 2m

P 2m

Total Pump Head: 27m 1000 USGPM, 416 TR

P 10m

DPT

Pump Power Calculated = 19.6kW

Efficiency of Primary Pump : 85%

M

Distributed Pumping System Pumping Energy

Primary Pump

Chiller

P 3m

P 3m

P 3m

P 3m

P 3m

P 2m

P 2m

P 2m

P 2m

P 2m

1000 USGPM Head For Primary Pump: 10m

200 USGPM

200 USGPM

200 USGPM

200 USGPM

200 USGPM

Head for Pump 1-1: 5m





P 10m

Energy Savings of 22% at design flow

48% Savings at 50% flow

Total Pump Power Calculated = 15.2kW

Efficiency of Distributed Pumps : 70%

Efficiency of Primary Pump : 85%

Pump Power Pump 1-1: 0.884 kW







Equipment/piping Pressure drop

Chiller = 25

Piping(10 flr x 13 ft/flr x 2 way x 4/100) = 10.4 ft

Fitting & valve (20% of piping) = 2.1 ft

AHU = 20 ft

Modulating valve = 30 ft..

Total = 87.5 ft

BHp = (87.5 x 1000)/(3960 x 0.7) = 31.5 Hp




Equipment/piping Pressure drop

Chiller = 25

Piping(10 flr x 13 ft/flr x 2 way x 3/100) = 10.4 ft

Fitting & valve(20% of piping) = 2.1 ft

Total (A) = 37.5 ft

AHU = 10 ft

Modulating valve = 0 ft.

Total (B) = 10 ft

A)BHp for Chiller pump

= (37.5 x 1000)/(3960 x 0.7) = 13.5 Hp

B)BHp for AHU pump

= (100 x 10) /(3960 x 0.7) = 0.36 Hp

0.2 Hp x 10 AHU = 3.6 Hp

BHp ( Chiller pump + AHU pump) = 17.1 Hp

Energy saving 31.5 Hp 17.1Hp = 14.4 Hp

14.4 Hp / 31.5 Hp = 45%

Unbalanced systems waste energy

Without balancing, to obtain design flow at the furthest unit, the system must be over-supplied with water.

Energy is wasted chilling or heating and pumping excess flow through the units closest to the plant room.

Old technology - Balancing via pipe sizing

It is virtually impossible to perfectly calculate frictional pressure losses through every pipe circuit at design stage.

The limited number of available pipe sizes makes it impossible select the perfect size for correct flow rate.

Extra large expensive valves are required to attempt to minimize re-adjustments.

Branches

Risers

Mains

Manual balancing requires extra valves

Control For Conventional System

T

DDC Return Air Temperature

CHWS

CHWR

Building Management System

M

Control For Distributed Pumping - maintaining constant T for a healthy system

T

DDC

Speed

chilled water T

CHWS

CHWR

Building Management System

Cooling load, CHW Flow Rate

Eliminate low T Syndrome!!!

Benefits to End User Actual Energy Savings over conventional design

100% balanced hydronic system

Save cost on commissioning and balancing the system

Eliminates low T Syndrome

Faster response of VSD pumps over modulating control valves

Save cost on modulating control valves, balancing valves or PICVs.

Save cost on buying smaller Primary Pumps (and installation)

The MAGNA3 is more than a pump

Key components that provide MAGNA3 energy efficiency

Optimised pump

hydraulics Composite rotor can

Compact stator

Neodymium

technology rotor

Patented differential

pressure sensor

New generation inline Pumps TPE3

nut

Clamp

Impeller

Bushing

Shaft seal

Motor stool

Shaft

Sensor and cable Neck ring

Pump housing

Coupling guards

Wide temperature range

Integrated Variable Speed Drive

Liquid temperature: -10oC up to +110oC

PN6, PN10 & PN16

Easy to install (no support structures)

Single phase power supply (230V)

Low Energy Consumption in the MAGNA3

Cooling Capacity 38TR CHW Flow Rate 20 CMH Coil Pressure Drop 4m

Magna3 65-60 Power Consumption 275W at design flow If average flow 12 ~ 16 CMH, input power < 100W

The MAGNA3 can be seamlessly

integrated to any BMS System in

your facility today.

BMS Integration

BMS Integration

BMS Gateway

BMS

Heat Energy Meter

Before

After

The Magna3 has an integrated BTU meter that measures heat energy consumption without the use of additional instruments.

INTELLIGENCE IN THE MAGNA3

Flow Measurement

The Magna3 has a flow measurement accuracy of 1% at design flow (blue region).

INTELLIGENCE IN THE MAGNA3 Magna3 40-100

Flow Measurement


Electromagnetic Flowmeter Dynamic Balancing Valve Magna3

MechanicsDetermine the fluid velocity by

induced voltage

Determine flow rate by

calibrated opening (orifices)

Determine flow rate by

pressure & pump speed

Highly dependant on

compliance to installation

requirements.

Independent of installation 1% at design flow

Typical catalog quote accuracy

0.5% of operating range (9 to 10

m/s)

2% of valve maximum flow rate

at 2 m/s

Accuracy @ pipe actual flow

rate 2 m/s : 1.8 to 2.25%

Installation

Requirements

Min 5D upstream & 3D

downstream to ensure any

accuracy

No specific requirements None

Differential

Pressure RequiredNo Requirements

Up to 80 kPa for valve max flow

rate of 2 m/sNone

Accuracy


FLOWLIMIT

Before After

FLOWLIMIT control function makes it possible to set a maximum flow

limit for the pump

Input/output

1 x analogue input (0-10V/4-20 mA)

2 x relay outputs

3 x digital inputs

Digital input

Relay output

Analog input

The Magna3 has integrated in- and

outputs points for sensors and

communication to BMS.

The no. of I/O points are:


Optimization

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.


GRUNDFOS GO Communication


Save time with the

intuitive handheld pump

control

Save and share reports

easy and electronically

Access to online

replacement and sizing

tools

Everything you need

on the GO

Two-pump wireless connection

Integrated wireless technology enables interaction between two MAGNA3 pumps

Connection to a parallel coupled pump is quickly and easily obtained with the built-in wizard or Grundfos GO

Two parallel coupled pumps can be controlled jointly in cascade mode, alternating mode or pump back-up mode

How your future AHU room may look like

Sample of Installation Magna 3 Hotel Tentrem

Sample of Motorized Control Valve

Running Power Status : flow and head Magna 3

Thank for Listening

Documents

Distributed Pumping Concept