Pump Armstrong PDF

Pressure Booster Systems Designers Handbook
CHAPTER 1: The Domestic Pressure Booster System

SECTION I: WHY IS IT REQUIRED? The pressure booster package is required when available street main pressure is not sufficient to serve the building. This pressure deficiency can be caused by a number of different reasons. Below are some of the most common: Loss of street pressure due to increased area population or development. Pressure loss due to the installation of a backflow preventer. Large flow volumes such as stadiums and office buildings reduce main pressure available. Aging piping which causes fouling thereby restricting flow through the pipe. Requirements within the building for minimum fixture pressures in order to achieve optimum performance. The booster system takes the existing street pressure and increases it to the preferred System Pressure. System Pressure refers to the pressure in the piping manifold after the pressure booster. It can be expressed by the following formula:
Suction Pressure + Boost Pressure - PRV Losses = System Pressure Where suction pressure is the available street pressure, boost pressure is the required additional increase added to the street pressure and PRV Losses are the pressure loss through the pressure reducing valves & the booster system piping.
Supply + Boost = System Pressure

Residual Pressure PRV Losses Static Pressure (height) Friction Loss
B O O S T
Supply Pressure (from City)

Relationship of Boost Pressure vs. System Pressure. Boost Pressure is what we design for. Supply pressure is that which is currently available. Combined, these form System Pressure.
TIP: Suction pressure can usually be obtained from a copy of the Fire Flow Test which provides suction pressures at various flows. Use the maximum system design flow to determine minimum suction pressure.
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SECTION II: INFORMATION REQUIRED There are minimum informational requirements in order to properly size a Booster package: Suction Pressure: mentioned in the previous section, current service available from the local municipality. Building Height: can be determined by number of stories (indicate distance between each level), or height can be taken off architectural elevations. Friction Loss: can be figured based on pipe distance or 10% of building height. Loss through Booster Package: Generally based on 5 PSI for the PRVs and interconnecting piping in the package (12 Feet TDH). Residual Pressure: how much pressure is required at the top of the structure after everything else is accounted for (i.e. pressure at the highest fixture).
SECTION III: SYSTEM CONFIGURATIONS Systems are available in the following most common configurations: Simplex = 1 pump system: One pump produces all flow and pressure Duplex = 2-pump system: System flow is usually split amongst (2) pumps, equally and un-equally. Triplex = 3-pump system: System flow is usually split among (3) pumps, equally and un-equally. Quadraplex = 4-pump system: Large system flows are split among (4) pumps, typically un-equally.
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CHAPTER 2: The Plumbing System

SECTION I: SIZING REQUIREMENTS Establish building dimensions Building height can be determined either by architectural drawings or # of floors times height/floor. (ex: 10 floors x 10 feet/floor = 100 Tall) Convert feet of water column to PSI by using the following formula: H x .433 = PSI
where H = Static Head; .433 is the mathematical reciprocal of 2.31, therefore, you will arrive at the same condition by dividing TDH by 2.31)
TDH A. STATIC HEAD - BUILDING HEIGHT B. FRICTION HEAD - FRICTION LOSS C. RESIDUAL PRESSURE REQUIRED (@ TOP) D. SYSTEM REQUIRED PRESSURE (A + B + C) E. MINIMUM SUCTION PRESSURE (SUBTRACT) F. SYSTEM BOOST PRESSURE (D - E) G. PRV LOSSES (5 -10 PSI) H. PUMP HEAD REQUIRED (F + G)
PSI
The table to the left indicates the various requirements in establishing system pressure rating. Typically, all figures are expressed in PSI using the Feet/PSI conversion formula and are then converted back to TDH to select the pumps.
Establish building flow capacity (see fig. #3 & 4) Count the number of fixtures which use domestic water. Bear in mind that different fixtures use water differently. (ex: 1.6 GPF Water Closet, 3.5 GPF Water Closet, Flush Valve, etc.) Determine the type of building from the flow chart which will indicate maximum required GPM. Be careful when selecting systems with a constant load, these systems will not benefit from a drawdown tank and system shutdown. (ex: Cooling tower, commercial laundry facilities, restaurants, night clubs, hydronic water make-up, etc.)
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WATER SUPPLY FIXTURE UNITS - WSFU

Heavy Use Assembly Other than Dwelling Units Serving Three or more Dwelling Units Individual Dwelling Units
TYPE OF FIXTURES
Bathroom Group, 1.6 GPF Gravity Tank Water Closet Bathroom Group, 1.6 GPF Pressure-Tank Water Closet Bathroom Group, 3.5 GPF Gravity Tank Water Closet Bathroom Group, 1.6 GPF Flushometer Valve Bathroom Group, 3.5 GPF Flushometer Valve Kitchen Group (Sink and Dishwasher) Laundry Group (Sink and Clothes Washer) 5.0 5.0 6.0 6.0 8.0 2.0 5.0 3.5 3.5 5.0 4.0 6.0 1.5 3.0
INDIVIDUAL FIXTURES
Bathtub or Combination Bath/Shower Bidet Clothes Washer, domestic Dishwasher, domestic Drinking Fountain or Watercooler Hose Bibb (1/2" Supply Pipe) Hose Bibb, each additional (1/2" Supply Pipe) Kitchen Sink, domestic Laundry Sink Lavatory Service Sink or Mop Basin Shower Shower, continous use Urinal, 1.0 GPF Urinal, greater than 1.0 GPF Water Closet 1.6 GPF Gravity Tank Water Closet 1.6 GPF Pressure Tank Water Closet 1.6 GPF Flushometer Valve Water Closet 3.5 GPF Gravity Tank Water Closet 3.5 GPF Flushometer Valve Whirlpool Bath or Combination Bath/Shower
1995 Change to the National Standard Plumbing Code adopted at NSPC Public Hearing - August 1994
4.0 1.0 4.0 1.5
3.5 0.5 2.5 1.0 4.0 1.5 0.5 0.75
2.5 1.0 1.5 2.0 1.0 2.0
2.5 1.0 1.0 1.0 0.5 2.0
2.5 1.0 1.5 2.0 1.0 3.0 2.0 5.0 4.0 5.0 5.0 6.0 4.0 3.5 8.0 7.0 10.0 1.0
2.5 2.5 5.0 3.0 7.0 4.0
2.5 2.5 5.0 3.0 7.0 4.0
2.5 2.5 5.0 5.5 8.0
Typical Fixture Unit Chart showing various types of fixtures and their relational fixture unit assignment. This is typically used by consultants to determine a fixture unit load which is interpreted on the building profile curves (fig. #4). This chart is taken from the National Plumbing Code, August 1994.
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Fixture Unit Chart

800 700 600 Total System GPM 500 400 300 200 100 0 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500 4750 5000 250 500 750 Hunters' Curve Hospitals Schools/Dorms Offices, Hotels, Low Rent High-Density Apartments
Total Fixture Units
The plumbing designer must consider the activities of the occupants and the building usage. Since this does not consider the human element, we rely on operating data and records compiled over the years by users, manufacturers and trade associations. The graph above is a representation of this information. This is typically what system flows are based on.
The National Bureau of Standards published report BMS-65, Methods of Estimating Loads in Plumbing Systems, by the late Dr. Roy B. Hunter. This report provided tables of loadproducing characteristics (fixture unit weighting) of commonly used domestic water fixtures as well as probability curves to estimate the capacity of the system. These curves are the basis for all manufacturers selection of Pressure Booster Systems. Over the years, the industry has further defined the Hunters Curve changing the probability of maximum flow in accordance with the type of building, since all structures do not use water in the same manner and frequency.
Special Services Dont forget that there are sometimes other systems which rely on the plumbing pumps for water make-up, service load, etc. These must be added in after you have determined the domestic fixture load. Examples of this are: Cooling Tower make-up water valve On-Site commercial laundry facility (Hospitals, Hotels, Dorms, etc.) HVAC System make-up load Boiler water make-up load Swimming pools Add these services in addition to the GPM arrived at from the charts.
TIP: Remember that when you add for special services, you will not have fixture unit references. You must add in the additional flow rate in gallons per minute AFTER you have used the fixture unit method to arrive at a total system flow rate. When this step is complete, simply add the additional GPM to the total system capacity for the extra services.
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SECTION II: SYSTEM CONDITIONS Establish current water system conditions Minimum suction pressure; this can typically be found on the Fire Flow Test, which is done on all buildings which require a fire system. Use the maximum design flow based on the flow condition calculated from fixture unit count. DO NOT ASSUME A MINIMUM SUCTION PRESSURE! Get this information from consultant or contractor. On cistern systems, be careful when you have a low NPSH. Suction lift is not recommended for a pressure booster system. Figure #5 through #7 explains the potential problems which can arise when an accurate suction pressure is not used to size the booster package.
TIP: In some cases, an incorrect suction pressure can contribute to potential problems. For example: If a system is designed using a minimum suction pressure of 20 PSI and a potential pump shutoff pressure of 140 (@ 0 GPM Flow), the capacity of the system could exceed minimum ratings if the suction pressure exceeds 40 PSI! In this case, the system will now EXCEED the 175 PSI working pressure, thereby, requiring a HIGH PRESSURE system design.
PSI
180 140 100 60
Shut-off Pressure Design Condition
PSI
180 140
Shut-off Pressure Shut-off Condition
X
Total Pump Pressure System Working Pressure
20 PSI Design Suction Pressure
X
Design Flow Pump Boost
20 PSI Design Suction Pressure
100 60
20
20
50
100
150
200
250
300
350
GPM
50
100
150
200
250
300
350
GPM
Pump design head is based on the minimum available (worst case) suction pressure plus the pump boost
Additional head is achievable when pump moves to shut-off. Although the PRVs will regulate downstream, upstream pressures can rise.
PSI
180 140 100 60
Shut-off Pressure Design Condition

W.P. #2
X X
Additional Pressures Dangerously High!
W.P. #1
In a worst case scenario as shown in the graphic to the left, when suction pressures are underestimated, there is a potential that the pressure could exceed the system rated working pressure.
60 PSI Actual Suction Pressure 20 PSI Design Suction Pressure

0 50 100 150 200 250 300 350
20
GPM
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SECTION III: FLOW SPLIT Select the best capacity split for the GPM capacity. In some cases, it is best to use an un-equal split rather than an equal capacity split. Much of this can be determined by either flow analysis (flow recorder mounted on system for a period of time in order to develop a usage pattern) or by some other less technical means. (i.e.: Typical load does not exceed 20% of system capacity for 70% of the day) Select a system manifold suited for the conditions and maximum flow Armstrong offers a number of different manifold materials to suit nearly every domestic water need. They are as follows: Cast Iron Flanged on either end. (includes (2) blind flange caps) Type K Copper Manifolds on Series 6500 (due to pump weight) Type L Copper Manifolds available on all other models Type 304 Schedule 10 Stainless Steel fabricated Schedule 40 Galvanized Steel fabricated Size manifolds according to the total system flow rate. See Figure #7 below for maximum recommended flows for system headers: Manifold Size 3 4 6 8 10 Maximum Flow (GPM) 300 500 1000 2000 3000
Fig. 7: The above chart represents the maximum recommended flow rates through the Pressure Booster System headers for various manifold sizes.
Rule of Thumb:
Duplex Systems - Un-equal split (33%/67%) becomes more cost effective at 200 GPM or higher. Triplex Systems - Un-equal split (20%/40%/40%) is more cost effective at 300 GPM or higher.
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PROBLEM 1: 1. Apartment building: 15 stories, 10/story = __________ X .433 = __________ PSI 2. Minimum suction pressure available is 30 PSI. 3. System is a retro-fit constructed in 1975 utilizing 3.5 GPF Water Closets. 4. There are 2.5 Baths/Unit, 5 Units per floor, each with a laundry room & kitchen. 5. Total # of Flow units = _______ Based on High Density Apartment Profile = _______ GPM. 6. There is a cooling tower on the roof which has a constant make-up demand of 30 GPM. 7. Available voltage is 208/3/60. 8. There is sufficient area at the top floor to mount a drawdown tank if required. 9. There are no special services on site. System Flow Capacity = __________ GPM System Output Pressure = __________ PSI System Header Size is _____________
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CHAPTER 3: Pump Selection Considerations

SECTION I: PUMP TYPES
Pump Types End Suction Details 175 # W.P., Low first cost, good use of floor space, typically 400 GPM or less, Low parts cost, relatively simple to repair, low to medium pressure boosting. 175# W.P., Low first cost, excellent use of floor space, more cost effective on larger flows, reasonable parts cost, very simple to repair, low to medium pressure boosting. 250# W.P., Medium first cost, excellent use of floor space, more cost effective on smaller flows (100 GPM and less), reasonable to high parts cost, reasonably repairable, medium to high pressure boosting (80-200 PSI) 250# W.P., High first cost, good use of floor space, more cost effective on very large flows and pressures, high parts cost, extensive repair work involved, medium to high pressure boosting at high flows. (50 + stories)
Vertical In-Line
Vertical Multi-Stage
Vertical Turbine
Note: W.P. stands for working pressure (i.e. suction pressure + boost)
SECTION II: OTHER CONSIDERATIONS 80% of all units will utilize End Suction Pumps. Consider multiple configurations for the pump type available. (ex: 6500, 6600 or 6700 Series, DualPak, QuadPak, etc.) Most systems should be considered to have an 18-20 year life cycle cost. Consider location of unit. (ex: Outdoors require TEFC motors)
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CHAPTER 4: Drawdown Storage Tanks

SECTION I: APPLICATION Tanks are to be used in systems that do not have a continuous water demand. (i.e. no make up water or Air conditioning etc..) Do Not assume that tanks will keep up with any appreciable service loads. Tanks should not be sized according to booster size. Tanks should be sized to store 20 - 30 Gallons of water (2 - 3 GPM leak loads) The capacity of the tank is determined by the cut-in and cut-out pressure of the booster system as well as the tank precharge pressure. (See Fig. # 8) Tank pre-charge is determined based on the mounting location of the tank. (See Fig.s # 9 12) Tanks maintain pressure in piping system and supply small demands allowing pumps to be shut down. Based on 20-30 Gallons of useable storage, the system will achieve a minimum shutdown of about 5 minutes based on a tank flow capacity of 2-3 GPM.
P U M P S T A R T P R E S S U R E psig 25 30 20 0.126 0.224 0.112 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 35 0.302 0.201 0.101 40 0.366 0.274 0.183 0.091 45 0.419 0.335 0.251 0.168 0.084 50 0.464 0.386 0.309 0.232 0.155 0.077 55 0.502 0.430 0.359 0.287 0.215 0.143 0.072 60 0.535 0.469 0.402 0.335 0.268 0.201 0.134 0.067 PUMP STOP PRESSURE 65 70 75 80 85 0.565 0.590 0.613 0.634 0.652 0.502 0.531 0.557 0.581 0.602 0.439 0.472 0.502 0.528 0.552 0.376 0.413 0.446 0.475 0.502 0.314 0.354 0.390 0.422 0.451 0.251 0.295 0.334 0.370 0.401 0.188 0.236 0.279 0.317 0.351 0.125 0.177 0.223 0.264 0.301 0.063 0.118 0.167 0.211 0.251 0.059 0.111 0.158 0.201 0.056 0.106 0.150 0.053 0.100 0.050 90 95 100 105 110 115 120 125
0.573 0.525 0.478 0.430 0.382 0.334 0.287 0.239 0.191 0.143 0.096 0.048
0.593 0.547 0.501 0.456 0.410 0.365 0.319 0.273 0.228 0.182 0.137 0.091 0.046
0.567 0.523 0.480 0.436 0.392 0.349 0.305 0.262 0.218 0.174 0.131 0.087 0.044
0.585 0.543 0.501 0.459 0.418 0.376 0.334 0.292 0.251 0.209 0.167 0.125 0.084 0.042
0.601 0.561 0.521 0.481 0.441 0.401 0.361 0.321 0.281 0.241 0.200 0.160 0.120 0.080
0.578 0.540 0.501 0.463 0.424 0.386 0.347 0.308 0.270 0.231 0.193 0.154 0.116
0.594 0.557 0.520 0.483 0.445 0.408 0.371 0.334 0.297 0.260 0.223 0.186 0.148
0.608 0.573 0.537 0.501 0.465 0.429 0.394 0.358 0.322 0.286 0.251 0.215 0.179
The chart above is a drawdown calculation chart. The numbers along the left side represent the call on pressure switch setting of the booster system. The top values represent the shut-off (shut-off = Pump shutoff pressure plus maximum suction pressure - best case) The corresponding intersection between any cut-in and cut-out value will give you the actual storage when multiplied by the total tank capacity.
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Remote Mounted Tank
When a tank is mounted at the top of the system, it can be pre-charged to the system pressure AT THE LOCATION OF THE TANK. This means that, if the system is rated for a 30 PSI residual pressure at the top of the building, the tank would only need to be charged at 28 PSI (we deduct 2 PSI just to verify that the tank is not overcharged. In addition, there is no need for a tank PRV since the tank is on the SYSTEM side which is REGULATED. In this case, we use the friction loss in the piping system to charge the tank. As the system begins to move toward shut-off, pressure increases in the piping due to the lack of friction, it is this increase that will charge the remote tank. Mounting the tank at the top of the system lowers the tank pre-charge allowing the use of a smaller or less costly noncode tank (if acceptable).
Skid Mounted Tank

When the tank is mounted onto the system skid, it must be regulated separately. A Tank piping connection is required (see Fig. #12) which will connect the high side of the pump to the tank. The connection will then T off to the discharge manifold with a separate tank PRV. This PRV is set 2 PSI higher than the system design pressure in order to assure complete exhaustion of tank contents. In cases where the tank is skid mounted, you should allow for about double the floor space required than for a remote mount or adjacent mount setup. Remember that the tank pressure will need to take into account System Pressure plus pump shut-off pressure, so this could force the selection into a code rated storage tank.
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Adjacent Mounted Tank
This seems to be the most popular method today of configuring the drawdown tank. The tank is mounted somewhere at the same level of the system (usually directly next to it, nearly always in the same room.) The tank piping and PRV are still required, but the tank connection is made in the field by the contractor rather than at the factory. The System Pressure plus pump shut-off must still be considered when considering the pressure rating, but the additional space required by the skid mounted tank can be partially avoided. Maneuverability and installation are also simplified. Piping connection is also mounted as in Fig. #12. Some advantages of this are that the system skid size is much more manageable and small versus the skid mount package.
SECTION II: PIPING CONFIGURATIONS

Tank is fed from high side of PRVs with 1/2 copper tubing. Tank PRV set @ 2- 5 PSI above P-1 pump pressure.
PRVs
Check valve holds against pressure backflow through pumps.
Water exits tank through same pipe
Suction Pressure
Tank Piping Schematic (Adjacent and Skid Mounted Tanks)

Tank feed line is piped into the High (pump) side of the Pressure Reducing Valves allowing full pump pressure plus suction pressure to enter the drawdown tank. When system is satisfied and pumps rise to shut-off, the thermal re-circulation line tells system to shut down. System leak loads are now provided for by the pressure tank through the separate tank PRV which is mounted to the discharge manifold.
TIP: There is a drawdown calculator located at the far right tab of ArmCalc entitled drawdown. Input the tank size in the top left cell. (Graph results will change when you press Enter) Read across the top of the graph for the pump start pressure (this is the same as the system on pressure which the pump package is trying to maintain) On the left side of the graph read down for the pump stop pressure. (in the case of an adjacent or skid mount tank, this is equal to the maximum possible suction plus pump shut-off at zero flow; For remote tanks, use the start pressure as the tank pre-charge and the stop pressure as the piping friction loss calculation. This is typically 10% of Static Pressure)
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CHAPTER 5: Pump Staging for Energy Efficiency

SECTION I: APPLICATION Consider alternate staging scenarios: One of the benefits you enjoy with Armstrong is a wide choice of pump selections, system configurations and staging scenarios. Make certain that you have exhausted all possible capacity splits. You may find that the total BHP used on an un-equal (33/67, 20/80, 20/40/40, 10/45/45) split may be less than an equal (50/50, 65/65, 33/33/33, 50/50/50) pump capacity split Dont encourage consultants to over-design redundancy. Redundancy is certainly reasonable to any design criteria, however there are ways to make the best use of the pumping power and still have redundancy. (Ex: Suggest that instead of using a 65/65% capacity split which adds un-necessary capacity to the system when the lead pump runs, take the design load, add 15% redundancy and suggest a 33/67 split where cost effective.) The redundancy is still built into the system, however the smaller pump will likely run most of the time.
SECTION II: PUMP SELECTION Typical capacity splits and reasons for choice: Duplex Possible reason for choice
Very economical (especially in system flows over 200 GPM), effective use of pumping power, ability to use 3-Step sequencing control optimizing BHP to Flow need. Preferable in system capacities below 200 GPM since motor H.P.s are typically the same as 33/67 split, allows auto lead alternation (equal wear), parts interchangeable Similar to reasons used in 50/50 split, however, allows for additional redundancy since (1) pump operating alone can handle a larger portion of the load. Provides full stand-by in the event of a pump failure, recommended for packages which are typically very small in H.P. since this is not effective use of BHP.
P-1
33% 50% 65% 100%
P-2
67% 50% 65% 100%
P-1
20% 30% 33% 30%
P-2
40% 40% 33% 70%
P-3
40% 40% 33% 70%
Triplex Possible reason for choice

Most common sequencing option, allows for up to 5-Step sequencing, very good use of pumping power, small lead acts as jockey pump for large periods of low-flow. Similar benefits to sequence above, however allows for up to 70% or 80% peak demand with (2) pumps running but has 10% built in redundancy. Typically used when minimum loads always exceed 20%, primarily used on hospital applications where loads are seldom low, this split only allows for 3-Step sequence. Provides a peak load of 100% when (2) pumps are running as well as an increased capacity and 70% system redundancy, not used very often.
Example of System Splits and use of multiple sequences In the following example of a 33/67% system split, a comparison is made on 50/50, 2 Step sequencing versus 33/67, 3 Step. Notice how dramatic the savings are by simply changing the existing system flow to sequence at un-equal capacities, as well as adding an additional step of control to the pump package.
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SECTION III: THE BUILDING LOAD PROFILE
W A T E R D E M A N D % D E S IG N C A P A C IT Y 100%
67% 50% 25%
12 A M
NOON
11
Typical residential building demand curve showing the relationship of system demand versus time of day. Notice how the system demand falls off in the early morning hours.
System demand is ultimately determined by flow. When a building uses water, it is related directly to the activities and usage habits of people and machines within the building. Since we size all systems to develop pressure, this demand has already been taken into consideration and the system is built to keep this pressure requirement at a constant pulse free state. It only makes sense that, since pressure is constant and the flow varies (requiring additional pumping power), that the sequencing of pumps be directly related to a measurable demand flow. Current sensing relays measure this work (GPM) exerted by the motor through the pump impeller. In figure #13 we can see how this demand fluctuates. You are not required to use the flow splits as shown in the example. Sometimes it is possible to optimize (i.e.: reduce horsepower consumption) by using a 20/80 split, for example. Because we use current sensing relays and we have the option of determining where the split is made, we can choose whichever split fits the application best.
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A Comparison of Energy Consumption for Varying Capacity Splits
*Note: The 33-67 Capacity Split reduces consumption by 29% and wastes 131% less power
12
10
Comsumption (in kWhrs)
50-50 Split
4
Actual Consumption 33-67 Split
0 0h00 1h00 2h00 3h00 4h00 5h00 6h00 7h00
8h00
9h00
10h00
11h00
12h00
13h00
14h00
15h00
16h00
17h00
18h00
19h00
21h00
22h00
Notice that by simply changing the flow split percentages, the pumps now follow the system demand more accurately. This is how to optimize power consumption with constant speed pressure booster packages. The system becomes, in essence, a variable flow package, choosing the best motor (or combination of motors) to run for a given GPM.
SECTION IV: SEQUENCING DEVICES There are currently a multitude of choices for pump sequencing. The most popular of these are flow switches, pressure switches & current sensing relays. Below is a description of each and the type of measurement each utilizes.
23h00
Time
20h00
Syrelec
Amperage
Hysterisis %
Flow Switch - senses water flow against a paddle which is in the water stream. Paddle moves a cam within the body which actuates next sequence. This is an accurate means of measuring flow, however, can be subject to corrosion and obstruction. (Direct Measurement of Flow)
Pressure Switch - The pressure switch senses a drop in pressure and activates a device or relay. They are available in both single point actuation and differential pressure. This mode of control relies primarily on the pump curve characteristics as they relate to pressure output. (Indirect Measurement of Flow)
Current Sensing Relay - The relay monitors amperage draw created by the motor as the flow increases through the pump. This amperage is set to a specific on time based on engineer requested sequencing. It is an indirect measurement of flow, but highly accurate. (Indirect Measurement of Flow via amperage)
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PROBLEM 2: 1. 2. 3. 4. You are replacing a Duplex system which has a design flow of 200 GPM. The system was designed around a 65/65 split. The system pressure is based on a boost requirement of 50 PSI. Analyze the difference between 65/65 split vs. 33/67 with a 15% redundancy factor. 65%/65% 33%/67%
Pump #1: GPM ________ H.P. ________ vs. GPM ________ H.P. _________ Pump #2: GPM ________ H.P. ________ vs. GPM ________ H.P. _________
Considerations Flow Switch - is in contact with the pumped fluid, therefore, it is subject to corrosion or obstruction. It can also fail mechanically. From a positive standpoint, the flow switch is a direct measurement of flow. Pressure Switch - is also in contact with the fluid and can be come clogged or fail due to corrosion. It is an indirect measurement of flow since it measures the pressure output of the pump as it relates to its curve. Suction pressures must be very accurate to facilitate an accurate sequencing scenario. Current Sensors - read the motor amperage draw as the motor works to generate flow through the pump. Since this work is directly proportionate to the flow the current sensor is measuring this in an indirect fashion, yet the amperage draw is very repeatable and highly accurate. Current sensors are not in contact with the pumped fluid, nor do they have any moving parts. They are also able to sense voltage change.
A word about non-overloading Many engineers (through their association with HVAC systems) have become very careful about specifying pumps which are non-overloading throughout their entire flow curve. If we look at the desired sequence in a system, however, we would like to use as much of the motor as possible before activating additional pumps in sequence.(see Section III of this chapter) This allows us to conserve power by managing the flow load. With a flow based measurement system, this can easily be done, since the consultant can dictate (right down to the exact flow rate) where the next pump will activate. Pressure switch based systems can be fooled by changes in suction pressure (which change the pump performance at any point on its curve) and therefore are unreliable for this purpose. In a properly designed system utilizing FLOW based sequencing, the engineer can indicate thatthe system shall be non-overloading throughout its entire SEQUENCE OF OPERATION rather than the individual pump curve.
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CHAPTER 6: Variable Speed Pressure Booster Systems Application and Design

There has been a lot of debate in the plumbing engineering community regarding the use of variable speed drives in domestic water pressure booster system applications. The debate centers on energy savings and whether or not there is a reasonable payback for building owners on the additional first cost of a variable speed system. This paper will shed some light on the issue, and perhaps provide design engineers with some tools to better understand when variable frequency drives (VFDs) make sense. The purpose of applying VFDs in a pressure booster system is to allow constant pressure regulation without the need for pressure reducing valves. There are four key elements to consider in the application of VFDs. The first has to do with the nature of the plumbing system, the second with the sequencing, the third with selection of pumps and hydraulic efficiency, and the fourth with the nature of the end users electrical service provider. SECTION I: THE PLUMBING SYSTEM A pressure booster is designed to account for five fundamental variables in any system: 1. Flow. The pressure booster must provide adequate flow under a wide range of demand conditions. 2. Residual Pressure. This is the minimum pressure required at the most remote fixture in the plumbing system. 3. Static Height. This is the elevation of the most remote fixture above the incoming supply main. 4. Supply Pressure. The worst case pressure on the supply side from the municipality must be considered in calculations. This pressure should be taken after the water meter and backflow prevention device. These devices can reduce the incoming supply pressure by as much as 15psi. 5. Losses. The friction loss calculation should include losses within the pressure booster system itself (typically about 5psi).
Supply + Boost = System Pressure

Residual Pressure Static Pressure PRV Losses Friction Loss Suction Pressure
Figure 1: The boost pressure is denoted by B and the variable pressures are denoted by V in the above illustration. The gray area is the opportunity for energy savings running a pump at variable speed in a domestic water boosting application.
B V
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In analyzing the practicality of using VFDs, we must now consider which variations of the above parameters yield energy savings when varying the speed of the booster pumps. Of the above five factors, static height and residual pressure generally do not change. As such they will have little or no impact and hence will yield no opportunity to vary the speed of the pumps. Variations in flow yield an opportunity for speed reduction since flow variations cause the pump to operate at different points on the pump curve. If the pump curve is steep, the opportunities for speed reduction and energy savings increase. Perhaps the greatest opportunity for energy savings is in the varying supply pressure. In some municipalities, this pressure can vary as much as 50psi due to daily peak demands or seasonal considerations such as irrigation in the summer. Finally, losses can potentially yield energy savings, as they are negligible at low flows. The additional pressure supplied for losses can be compensated for if the pressure sensor for the system is located remotely in the plumbing system. You will note that a constant speed pump will operate along the characteristic pump performance curve (upper curve) with the PRV limiting the pressure to the desired constant discharge pressure. The variable speed pump will operate along the system curve (lower curve) by varying the speed of the motor driver.
60
50
Design Point
40
3500 rpm Constant 1950 rpm Constant VFD Control Curve
30
V B
PSI
20
10
0 0 20 40 60 80 100 120 140 160 180 200
Flow
Figure 2: Once again, the boost pressure is denoted by B and the variable pressures are denoted by V in the above single pump performance curve. The gray area is the opportunity for energy savings running a pump at variable speed.
Of the above factors, the variable pressure parameters are quite easily calculated; however, flow adds a dimension of complexity to the overall analysis. This is due to the measure of uncertainty in building demand or load profile of the system. To be precise, we would be able to exactly calculate the energy savings yielded by a variable speed system using the following formula (allowing the t time increment approach zero):
E = (QPt/)constant speed - (QPt/)variable speed
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Clearly, there are a number of uncertain parameters in this formula. It is useful for analysis purposes to make assumptions to yield a quicker estimate of potential energy savings in the system. For illustration purposes, we will look at a single pump and system resistance curve to better understand the analysis of such a system. Further, for the purposes of simplicity, we need to make some assumptions before we begin our analysis. 1. Load Profile (Q). This can be estimated in as much detail as desired. For the purposes of this article, we will look at an average building load assuming 50% of design flow for a single pump designed for 200gpm. The same analysis can be done using multiple pumps, multiple time increments, and average loads during those time increments to increase the accuracy of our results. 2. Efficiency (). Both pump and motor efficiencies at the average demand are assumed to be 65% and 85% respectively. 3. Variable Pressure (P). We will assume the variable pressure to be daily rather than seasonal. Seasonal variations will yield reduced savings since the high pressure is only experienced during a given period of the year. For the analysis, we will assume a boost pressure of 80psi with 10psi of losses, 10psi of supply pressure variation, and 10psi pressure rise to shutoff based on the pump curve. Thus, the total P will be 30psi from zero flow to the design 200gpm. In addition to the above assumptions, we will approximate the variations in pressure across the operating conditions as being linear. At 100gpm, we can then assume the pump head to be 85psi, and the suction variation and friction losses to be 5psi each. As a further assumption, we must assume some loss in the drive itself. For the purpose of simplicity, we will approximate this at 3%. The above assumptions yield the following daily energy savings for the pump considered:
E = (QPt/)constant speed - (QPt/)variable speed E = [(100gpm)(85psi)(2.31)(24hrs)/(85%)(65%)(3960)] - [(100gpm)(70psi)(2.31)(24hrs)/(85%)(65%)(97%)(3960)]

A savings of 32.5kWhrs per day is realized. At $0.10/kWhr, the daily savings for a building owner would be $3.25 yielding an annual energy savings of $1,186.25.
SECTION II: SEQUENCING CONSIDERATIONS The above analysis simply considers the operating conditions in the plumbing system and neglects one key feature of pressure boosters: pump sequencing or staging. The controls and data available when using VFDs can yield additional energy savings if applied intelligently. The key consideration in sequencing is maximizing pump efficiency. When VFDs are applied and pumps are sequenced based on a single parameter such as speed (as in the case of a system with a single variable speed pump and constant speed lag pumps), pumps operate anywhere on the curve with no opportunity for maximization of pump efficiency. The same is true of pressure, flow, or kW sequencing. Monitoring multiple parameters allows pumps to be sequenced based on the location on the pump curve. In this case pump efficiency can be maximized yielding additional savings. You will note that operating the same pump at 75% efficiency rather than 65% yields 15% in energy savings.
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Best Operating Algorithms and the Need for Equally Sized Pumps In conventional, constant speed systems, it is common for a small lead jockey pump to be applied to operated during off-peak hours. This works well on constant speed systems, but presents a few problems in a variable speed system. Unequal pumps perform hydraulically differently due to their different characteristic performance curve. If pumps are sized unequally, there are two choices one can make on the proportional, integral, derivative (PID) pressure control: a) Independent PID for unequal pumps This is inherently unstable and generally is not used. The instability is due to the PID for one drive working against the PID in the other. One drive speeds up while the other slows down - this is a cyclic effect and is difficult to control without dramatically reducing the system response time. The damping required in the PID leads to fluctuation in pressure actual pressure vs. the set point pressure. b) Single PID for all pumps If the pumps are not equal and operating at the same speed, the pumps will operate on the curve at the point of intersection of the two pump curves. This is equivalent to a constant speed system operation and does not gain any energy savings other than that available in the PID (pressure regulation). What happens is that since the smaller pump has a steeper curve with higher shutoff head, when two pumps are running, the smaller pump runs at the end of it's curve (inefficient point) and the larger pump runs near shutoff to the left on the curve (another inefficient point). The above choices are further complicated by the problem of when to sequence pumps on and off. The decision to sequence pumps requires flow, differential pressure, and speed inputs with a complex algorithm to sequence optimally. This has not been demonstrated to work properly in application. Any sequencing algorithm based on single inputs such as pressure, speed, flow, or power consumption is flying blind there is no way for the pump controller to know how efficiently the pumps are operating and what combination of pumps is the best choice. By sizing pumps equally, PID stability is easily achieved the equal pumps perform at the same location on the pump curve. Combining this with a best operating point (BOP) sequencing algorithm, sequencing of pumps based on a location on the pump curve regardless of speed, pressure, and other system-related factors is possible. Clearly, there is a great opportunity for energy savings based best hydraulic performance considerations. This design principle also makes a system easily adjustable in the field under varying operating conditions.
SECTION III: PUMP SELECTION By convention, pumps are selected so that the design operating point is to the left of the best efficiency point (BEP). Lets examine why. Traditionally, pumps have been sized with additional pump head to ensure the needs of the system are met. In a traditional constant speed pressure-sequenced system, the second pump would be sequenced on (turned on) when the first pump begins to run to the right of the design point on the pump curve. This is due to the excess head in the initial calculations. Since there was no way to account for this pump head in application other than throttling of the pump, design yielded pumps which operate and are sequenced to the right of the best efficiency point.
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60
50
Traditional Design Point
Best Design Point
40
30
PSI
20
Best Efficiency Point (BEP)
10
0 0 20 40 60 80 100 120 140 160 180 200
Flow
Figure 3: Traditional pump selection does not apply in variable speed pressure boosting if best operating point sequencing is applied. Designing to the right of the best efficiency point maximizes system hydraulic efficiency.
If this same assumptions are applied in a flow-based (current, kW, or flow) or best operating point sequenced system, pumps never operated to the right of the design point. In fact, additional pumps are sequenced on just when the pump begins to perform efficiently. This means that the system runs more pumps than necessary, and that the pumps are operating at less efficient locations on the pump curve. With the above knowledge, it is clear that pumps in a flow-based or best operating point sequenced system should be selected to the right of the BEP. This strategy yields additional savings in two ways. The first is that the system will leave a single pump operating when it is close to its BEP maximizing pump efficiency. The second is that selection further to the right on the pump curve yields additional pump shutoff head. This increased shutoff head increases the gray area in the illustrations. The steeper rise to shutoff yields greater speed reductions at low flows, and consequently additional energy savings.
SECTION IV: ELECTRIC UTILITIES AND BILLING POLICIES The final consideration in the application of VFDs applies for any piece of mechanical equipment that uses an electric motor. Intuition and rudimentary economic theory support a model in which a commodity or service is bought and sold based on an agreed upon price. The total amount paid is proportional to the net amount of commodity or service provided. One apple is $1. Ten apples are $10. In a free market, the price will fluctuate based on the availability (supply) and the need (demand) for the commodity or service. The principle is very intuitive. The problem with the above model is that the bandwidth of the transaction or delivery pipeline is assumed to be infinite. If we apply a capacity constraint to the pipeline, the theory of supply and demand breaks down. Plenty of a particular commodity may be available, but the demand may remain unmet.
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Electric utilities have the pipeline problem. A customers demand for increased bandwidth hurts the electric utility in two ways: it must increase the size of the pipeline (upgrade the distribution grid), and must produce more power to cover the higher theoretical peaks based on the increased bandwidth of the distribution grid. In theory, unused bandwidth is unusable to the utility. Further, unused bandwidth demands that the utility have enough power to handle the relatively rare case when the full capacity of the pipeline is needed. Electric utilities around the world use various strategies to deal with this very scenario. One means of managing the pipeline problem is to charge customers not for the amount of product used, but for the size of the pipeline required to deliver peak power to the customer. This has significant implications for application of electric motors. The starting current required to start a motor turning can be as high as 10 times the actual operational full load amps. It is this peak that the end user will pay for. By reducing the starting current, therefore, one can yield enormous savings for an end user. VFDs accomplish this task by soft-starting and soft-stopping motors. Inrush amps are drastically reduced, and in cases where the utility charges pipeline penalties, energy bills for the entire building can be cut by as much as half by applying VFDs. Conclusion In closing, it is useful to consider some general rules for application of VFD pressure booster systems. Some prime examples for application of VFDs in pressure boosters are as follows: 1. Buildings with long runs of piping such as schools and hospitals 2. Buildings with undersized piping such as older apartment buildings 3. Buildings requiring 10hp or larger pumps (larger motors yield greater savings when using VFDs) 4. Neighborhoods with varying supply pressures. 5. Where the electric utility charges for daily or hourly peak power rather than for cumulative power consumption. Further to energy considerations, VFDs may be applied to solve other problems in a system such as water hammer or excessive maintenance of pressure reducing valves. Other considerations aside, the key factors to consider are variable pressure in the system, load profile, pump selection, and sequencing strategy. Variable speed systems will save energy in any application. Achieving a reasonable payback time for building owners is the key consideration. When these factors are considered, the payback can be significant.
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CHAPTER 7: Control Panels

SECTION I: OVERVIEW Controls The controls for Armstrong Booster Systems consist of an electric circuit which operates the starters of the motors. The panel is supplied by the same power source as the booster motors. The controls are housed in a NEMA rated enclosure and are composed of a series of monitoring, control, and logic components. Understanding the circuit schematic can make life much easier in the field when starting up, fine-tuning, and maintaining a booster system. Often, problems which arise in the operation or start up of a booster system are linked to the controls even though the problems may seem to be with the motors and pumps, or the piping and valves of the system.
Safety Because of the high voltages required by the motors, safety cannot be emphasized enough in making adjustments to the controls. The Bad News: Some of the wires inside the panel are live, even when the panel door is open. Always consult the instructions on the inside of the panel door or this manual if you are unsure of the proper safety procedures. The Good News: The circuits will not store latent charge when the panel power is off since there are no capacitors in any of the circuits. Result: No nasty shocks from residual charges stored in the circuits.
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Schematics Schematics for electric circuits can be confusing. With this in mind, this handbook was composed to remove the guesswork by using block diagrams to explain the schematic symbols. Two important terms need to be understood at this point. Electricians use the terms open and closed circuit. OPEN means there is a break in the circuit preventing current flow. CLOSED means the circuit is continuous and unbroken allowing current flow. These definitions lead to a basic rule: OPEN = OFF (no current flow/cold wire) CLOSED = ON (current flow/hot wire) Components of circuits such as switches and relays are often spoken of in relation to these terms. A Normally Open component in its usual state breaks a circuit preventing current flow. A Normally Closed component in its usual state keeps a circuit continuous allowing current to flow. Schematic symbols for a component indicate whether it is normally open or normally closed. Note: The normal state refers to the position of the component (either open or closed) as that component would be in the DE-ENERGIZED, DE-PRESSURIZED state. To clarify, all pressure switches appear as they would with zero pressure, and motor overloads appear as open (even though during normal operation, these components are closed!). Another important element of the schematic is the list of reference numbers printed vertically on the left hand side of the diagram. These numbers are location references for contactor and relay coils. You will see that to the right of each contactor and relay coil is a list of numbers in brackets. These numbers give the location of the switches actuated by the coils on the diagram. These are not to be confused with terminal numbers which either appear as labels on arrows or are enclosed in boxes on the schematic. To locate the switch actuated by the coil: a) Read the numbers to the right of the coil. b) Go to the corresponding numbers on the left side of the schematic. c) Search the schematic to the right of the reference number horizontally until the switch is located.
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Lastly, please note that all schematics shown in this handbook are for a three phase Duplex Booster System. These provide examples you can adapt as required when reading schematics in the field. The Basic Control Panel Circuit Every control panel for Armstrong Booster Systems can be broken down to the following components plus the additional options selected by the customer: a) Main Disconnect and Motor Protector Circuits b) Power Transformers and Panel Protection Circuits c) Pump Selection and Shunting Circuits d) Current Sensing and Control Relays e) Pump Protection Circuits and Alarms
C O N T R O L /L O W V O L T A G E S ID E
PO W ER TRA N SFO RM ER AN D P A N E L P R O T E C T IO N
M O T O R /H IG H V O L T A G E S ID E
M A IN D IS C O N N E C T AND M OTOR P R O T E C T O R C IR C U E T S
P U M P S E L E C T IO N A N D S H U N T IN G C IR C U IT S
C U R R E N T S E N S IN G AN D CON TROL RELAYS
P U M P P R O T E C T IO N A N D A LA RM S
G rou n d
Block Diagram of Complete Control Circuit
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The block diagram on the previous page depicts this schematic. As each component is discussed, refer back to this schematic to identify where each element is located.
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SECTION II: MAIN DISCONNECT and MOTOR PROTECTOR CIRCUITS
POWER
TRANSFORMER
MAIN DISCONNECT SWITCH SHORT CIRCUIT PROTECTOR
OVERLOAD PROTECTOR
Control Panel Motor &Pump System

Block Diagram of Main Disconnect and Motor Protector Circuits
Main Disconnect Switch The main disconnect is the main power switch for the entire booster system. All Panel and Motor servicing should be performed with the main disconnect in the OFF position. Setting the HAND-OFF-AUTO (H-O-A) switches to the OFF position does not disconnect power from the controls. The main disconnect switch releases the control panel, motors, and pumps from the power supply. As a safety feature, the panel door cannot be opened without first switching to the open (OFF) position. The main disconnect dial/switch is located at the top right hand corner of the panel. Warning: Though the open panel is not live, the wires entering the panel to the disconnect at the top of the panel are LIVE. DO NOT TOUCH.
Schematic of Disconnect Switch. The location of the switch on the panel is indicated by the arrow.
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Motor Protector Circuits Every panel houses a protection circuit for the motors. These circuits consist of two basic components: a) Short Circuit Protector: This is a quick-trip breaker which protects the motor from potentially damaging current surges. Typically, the short circuit protector will trip on 13 times the full load amps of the motor (maximum motor current rating). b) Overload Protector: This bi-metal trip device is heat sensitive and will trip if the current to the motor exceeds the motor current rating for more than a given period of time.
The short circuit protector (left) and overload protector (middle) combine to form a complete motor protector circuit (right). Within the controller, these components are integrated into a single component called an overload relay. The device has a setting for the maximum allowable amperage, and a two push button circuit breaker (pushing in the red button opens the circuit / pushing in the white button closes the circuit).
These circuits are separated from the actual motor starter by a set of contacts which turn individual pumps on and off as required by the flow demand conditions. The logic for pump switching is contained in the pump shunting circuit and relays discussed in Sections IV and V. A schematic showing the main disconnect and motor protection circuits is shown below.
Main Disconnect and Motor Protection Circuit. Note that the lower segment of the diagram (marked P1 and P2) represents the motors and their respective starters.
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SECTION III: POWER TRANSFORMERS and PANEL PROTECTION CIRCUITS
CONTROL TRA N SFO RM ER
POW ER ON
CONROL C IR C U IT BREA KER
C o n tr o l P a n e l C ir c u it
Block Diagram of Power Transformer and Panel Protection Circuit
Control Transformers The control transformer separates the motor side (high voltage) from the control side (low voltage) of the booster system. The control transformer steps down the voltage to the control panel. Though the motor may use three phase 208V to 600V power, the control portion of the panel always runs on single phase 115V power. The transformer takes care of this voltage conversion.
Control Transformer. The left side is the low voltage side providing power to the panel. The right side is the high voltage supply which powers the motors.
Control Circuit Breakers A control circuit breaker protects the more sensitive components (relays and contacts) from being damaged by current surges. This standard circuit breaker trips at 0.5 amps to 3.0 amps depending on the systems combined horsepower.
The control circuit breaker prevents current overloads in the controls' sensitive components.
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Power On Pilot Light A pilot light indicates that power is being supplied to the controls. Provided that the control circuit breaker is closed, this pilot should be lit.
The Power On pilot light informs the controls operator that the panel is live.
We now are able to discuss the fundemental panel protection and motor protection circuits. On the schematic, the main power source is supplied at the right of the disconnect switch. This power supplies the motors via the motor protector circuit and is stepped down to the panel voltage via the transformer. This is the junction that separates the high voltage (motor) side from the low voltage (control) side of the control panel. The control circuit breaker then protects the controls from current surges. All things being normal, the panel is supplied with power lighting the Power On pilot light. This circuit can be seen below.
Control Protection, Transformer and Motor Protector Circuits. The portion of the schematic on the left side of the dashed line was discussed in this section.
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SECTION IV: PUMP SELECTION and SHUNTING CIRCUITS
LA M P H -O -A PUM P S H U N T IN G C IR C U IT H -O -A STA RTER #2 STA RTER #1
ALTERN ATO R S W IT C H
LA M P
F r o m P r e s s u r e S w itc h
Block Diagram of Pump Selection and Shunting Circuits
Manual Alternator Switches Manual alternator switches are standard for 50-50 capacity split Duplex systems and for the two lag pumps in the Triplex systems. The switch allows selection of which pump is the lead pump. This allows the operator of the system to equalize wear on the motors and pumps by periodically changing the alternator setting. The switch is a standard selector switch (marked either P1-P2 or P2-P3) located at the bottom center of the panel.
Manual alternator switch determines which pump leads.
Automatic Alternator Switches Automatic alternator switches are optional on units requiring alternation of the lead or lag pumps. The switch serves the same purpose as the manual selector switch. The switch is designed to alternate on every no-flow condition and on shutoff of one pump after a full flow condition.
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Pump Shunting Circuits The shunting circuit controls the turn-on and shut-off of pumps in the Duplex and Triplex booster systems. This circuit contains the logic which sequences the booster system. The shunting circuit is governed by the readings of one or more current sensing relays (see Section V on current sensing relays). The current sensing relay causes control relays to open and close contacts in this circuit. This action starts and stops the motors in response to the flow demand. The circuit is only activated when all the pumps of the booster system are set to the AUTO position on their respective H-O-A switches.
Pump Shunting Circuit holds key to pump sequencing. The circuit is only activated when the pumps are placed in the AUTO position.
Pump Run Indicators and Motor Contactors Pump run indicator lamps (Pilot Lights) are placed in parallel with the contactor coil for each motor. The contactor coil actuates a contact located between the motor protector circuit and the motor to close. The closed contact supplies power to the motor and starts the pump running. This connection also lights the pump run lamp on the panel allowing the operator to know the status of each pump of the system.
Pump run indicator and contact coil in parallel. The coil closes contacts starting a motor.
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Pressure Booster Systems Designers Handbook SECTION V: CURRENT SENSING and CONTROL RELAYS
CONTROL RELAY #1
CONTACT #1 SHUNTING CIRCUIT CONTACT #2
CONTROL RELAY #2
CURRENT SENSING RELAY
RUN PERIOD TIMER
Current Sensing and Control Relays
Current Sensing Transformers One leg of each motor lead is passed through a current transformer coil. These coils measure the current drawn by each motor, indirectly measuring the GPM flow through each pump. The current sensing relays supplied by the current transformers are factory set to an upper and lower current threshold. When the current exceeds the upper threshold, an additional pump is turned on to cope with the increased flow. Likewise, when the current drops below the lower threshold, a pump is shut down to conserve energy. The upper threshold controls the turn-on of the next pump and is adjusted by the dial marked Threshold on the current sensing relay. The lower threshold controls the shut-off of a running pump. It is set as a percentage of the upper threshold using the dial marked Hysteresis on the current sensing relay.
Current Sensing Relay. In combination with a control relay, the CSR activates a current transformer in the starter (part of the contact arrangement) to start the motor. The numbers 19 and 20 marking the arrows indicate a connection to the matching numbers on the motor lead.
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TIP: The number of current sensing relays in a system can be determined by the formula: DUPLEX: ONE RELAY + ONE RELAY PER STEP OF SEQUENCING TRIPLEX: TWO RELAYS + ONE RELAY PER STEP OF SEQUENCING EXAMPLE: A Duplex System on 33-67 capacity split supplies a peak demand of 300GPM. The system is designed for conventional sequencing (i.e. The lead pump runs constantly. The lag pump turns on and off as the flow demand requires). The motors are 5 and 10 hp and run on a 208V supply voltage. At full flow, the lead pump draws 50 amps. The system has one current sensing relay. The current sensing relay turn-on threshold would be set to 50 amps. This would cause the lag pump to turn on when the lead pump draws 50 amps. The shutoff threshold would be set to about 60 amps. This would cause the lag pump to shut off when both motors together draw 60 amps. The Hysteresis setting would be 20%. Reason: 20% of 50 amps is 10 amps. Fifty amps (upper threshold) plus 10 amps gives a shutoff threshold of 60 amps. Why is the shutoff threshold set higher than the turn-on threshold? This is because two motors working at the same flow rate as one motor alone will draw more amps.
Current Sensing Relay Switches Every time a current sensing relay coil reads a threshold current, it actuates a current sensing relay switch to either open or closed (depending on whether the switch is normally open or normally closed).
Current sensing relay switch closes actuating a control relay to start or shut down a motor.
As the relay coil requires, this relay switch will open or close causing one of the following to happen: a) The switch closes causing a control relay to turn on a pump.. b) The switch opens starting the countdown on the minimum run timer. When the timer runs down, a control relay turns the pump off.
CURRENT SENSING RELAY COIL
CONTROL RELAY COIL
MOTOR CONTACT
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Control Relays A control relay coil is actuated by the closing of a current sensing relay switch. The control relay in turn actuates a contact to close starting a motor. This coil, once activated will not deactivate with the opening of the current sensing relay switch. Instead, a minimum run timer holds the circuit closed until the timer has run down. This feature prevents cycling of pumps during near-threshold flow conditions.
Control Relay Coil actuates the motor starter contacts inside the shunting circuit.
Contacts A contact corresponding to each control relay is located in the pump shunting circuit. The contact reacts to the coil in turn actuating the motor contactors and will do one of the following: a) Turn on a new pump and shut the running pump off. b) Turn on a new pump and leave the running pump on. c) Shut off the running pump after the set time.
Contacts (RP2) close to start the motor running or open to shut one down. This action opens or closes the motor contactors (C1).
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Minimum Run Timer A minimum run timer for each current sensing relay ensures that pumps do not cycle damaging the motors. The timer is started when the current sensing relay opens. The timer keeps the control relay energized and the corresponding contact closed. The result is that instead of the pump corresponding to the control relay turning off, the pump keeps running for the designated time period. After this time, the connection is opened and the pump turns off. For example, if the timer is set for 5 minutes, and a pump is turned on, it will stay on for at least five minutes. Cycling of the pump can only occur at five minute intervals preventing cycling damage to the motor and pump.
Timing Relay holds the contact for a set period of time in order t o prevent pump cycling.
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SECTION VI: PUMP PROTECTION
Circuit Breaker
PRESSURE SWITCH
Transformer
PUMP SYSTEM
AQUASTAT
SOLENOID VALVE
Block Diagram of Pump Protection Circuit
Low Suction Pressure Warning A pressure switch protects the pumps from the effects of low suction pressure. If the suction pressure feeding the system drops below a minimum threshold the low suction pressure switch will open, shutting all pumps down. The minimum suction pressure cut-out is factory set to 5 psi but may be adjusted, though this is strongly advised against. The low suction switch will turn all pumps off and light the low suction lamp warning. The pressure switch has two settings: a) Cut-out value: This opens the contacts shutting down the pumps (set at 5 psi). On the switch itself, this setting is adjusted by turning the top screw. The actual setting is read on the scale on the side of the switch. b) Cut-in value: This is adjusted relative to the cut-in value using the Differential setting. (Cut-out value + Differential Setting = Cut-in Value) The differential is set after the cut-out value has been set, and should be set to its minimum to begin adjustments. After the cut-out has been set, turn the bottom screw to the letter corresponding to the desired differential. (Factory set to 5 psi above the cut-out pressure.) Warning: If the low suction pressure switch is set too close to the minimum NPSH, pump cycling will occur. If the situation is not corrected, damage to the motor starters can be expected. The same problem will occur if the Differential setting is too low.
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Fig.# 21: Low suction pressure switch shuts down system and warns by lighting pilot.
High and Low System Pressure Warnings Two further pressure switches with warning pilots are available as options (see Section VII of this chapter). These switches are also factory set and can be complimented by corresponding low and high system pressure warning lamps. Aquastats and Solenoid Valves During normal operation, a steady flow of water through the pumps carries away the waste heat they generate. Because of this, high temperatures are occasionally generated during periods of low flow. High temperature water can affect the performance of and even damage the pumps. An aquastat is available as an option and is installed on the suction header to measure the temperature of the water in booster system. The aquastat is set for a certain temperature (120F) at which it actuates a solenoid valve located on the side of the control panel. This valve opens bleeding the potentially harmful hot water. In No-Flow Shutdown Systems (Option X), the aquastat is used to trigger a pressure switch which shuts down the system. In this case, no solenoid valve is required since the aquastat is set to a much lower temperature (90F).
Aquastat and Solenoid valve act together to bleed high temperature water from the pumps. On No-Flow shutdown systems, the solenoid valve is not necessary since the pumps shut down long before high temperatures are generated.
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SECTION VII: OPTIONS No-Flow Shut-down No-Flow Shut-down (Option X) is an energy saver option, and requires a drawdown tank. Though this incurs an initial cost, on systems where no flow conditions occur for several hours a day (i.e. office buildings, etc.), the energy savings can be dramatic. Typically, the option pays for itself within the first two years of operation. The No-Flow Shut-down option uses an aquastat to trigger the shutdown. The aquastat is set from its usual 120F to 90F. This typically shuts the system down after about three minutes of a no demand condition. No solenoid bleed valve is required since the system shuts down well below the usual 120F threshold. The aquastat may need resetting depending on the ambient water temperature of the particular location. Check the troubleshooting guide or instructional video before resetting the aquastat. The drawdown tank maintains system pressure and handles leak loads while the pumps are not running. A call on pressure switch triggers the lead pump to turn on when a demand is placed on the system. Enclosures Though the NEMA 1 Enclosure is Standard for Armstrong Booster Systems, a wide range of indoor and outdoor enclosures of varying protection ratings are available as options. Be sure the enclosure suits the needs of the customer by refering to the listing of NEMA, CSA, and UL standard codes for control panel enclosures on page 40 of this handbook. Alarms A variety of alarm options are available. All are visible warning lamps and may be complimented as required by Option H, the audible alarm buzzer (linked in parallel) with the standard alarm lamp. The following alarms are offered: a) High System Pressure: This option (Option K) is simply a pressure switch with indicator lamp on a bypass circuit much like the low suction pressure alarm. This alarm is accompanied by a system shutoff and a manual reset button on the panel door. b) Low System Pressure: Two different low system pressure alarms are available. Be sure to quote the correct option on orders. Option AD will shutdown on the low system pressure condition. Option Q will turn on another pump to compensate for the low pressure. This pump will remain engaged until the reset button is pushed. Both options have manual resets. c) High Suction Pressure: Option G is also a bypass type pressure switch which will shut the system down on high suction pressure readings. This option has automatic reset when the suction pressure drops below the set threshold pressure. d) Low Suction Level Shutdown: Option AE e) Motor Overload Lamps: Option D is mounted on the motors themselves. The lamps will light if the motor current level exceeds the set overload current. Automatic Alternation Automatic pump alternation (Option I) is available on a 24 hour/7 day per week time clock, or automatically after every full demand and no-flow condition. Instructions for programming the timer are included inside the panel door with every order on this option. The timer controls a relay which toggles the pump alternation switch at the time set on the clock (daily or weekly).
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HydroSaver Sequencing The HydroSaver Sequencing options (Option S, T, and U) require the addition of an extra control relay per stage of sequencing. Though there is a cost for this option, this cost is often offset within the first two years of operation in energy savings. Option S adds three step sequencing to a Duplex system typically using a 33-67 capacity split between the two pumps. The arrangement leads to the following pump run conditions depending on the demand flow: Step 1: Pump 1 running, Pump 2 off (33% capacity) Step 2: Pump 1 off, Pump2 running (67% capacity) Step 3: Pump 1 and Pump 2 Running (full capacity)
Option T adds four step sequencing to a Triplex system using a 20-40-40 capacity split between the three pumps. The arrangement yields the following pump configurations subject to demand conditions: Step 1: Pump 1 running, Pumps 2 and 3 off (20% capacity) Step 2: Pump 2 running, Pumps 1 and 3 off (40% capacity) Step 3: Pumps 2 and 3 running, Pump 1 off (80% capacity) Step 4: Pumps 1, 2, and 3 running (full capacity)
Option U takes full advantage of the Triplex 20-40-40 capacity split by breaking the supplied flow into five steps: Step 1: Pump 1 running, Pumps 2 and 3 off (20% capacity) Step 2: Pump 2 running, Pumps 1 and 3 off (40% capacity) Step 3: Pumps 1 and 2 running, Pump 3 off (60% capacity) Step 4: Pumps 2 and 3 running, Pump 1 off (80% capacity) Step 5: Pumps 1, 2, and 3 running (full capacity)
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NEMA 1 General Purpose - Indoor Intended for indoor use. Provides protection from accidental contact of personnel with enclosed equipment. Standard Armstrong enclosure. NEMA 2 Dripproof - Indoor Intended for indoor use. Protects equipment from falling dirt and falling non-corrosive liquids. NEMA 3 Dust, Rain, and Sleet resistant Outdoor Intended for outdoor use. Protects enclosed equipment from wind-blown dust and water. Limited resistance to snow, sleet, and ice. (NOT SLEET PROOF) NEMA 3R Rainproof / Sleet-resistant - Outdoor Same as NEMA 3 with added resistance to rain and snow. NEMA 4 Water/Dust-tight - Indoor/Outdoor Intended for indoor/outdoor service. Protects equipment from splashing, seeping, falling, or hose-directed water and from severe external condensation. Limited resistance to snow, sleet, and ice. NEMA 4X Water/Dust-tight - Indoor/Outdoor Corrosion Resistant Same provisions as NEMA 4 with the addition of resistance to corrosion. NEMA 12 Indoor Industrial - Dust and Drip-tight Intended for indoor use. Protects equipment from fibers, flyings, lint, dust and dirt, and light splashing, seepage, dripping and external condensation of noncorrosive liquids. NEMA 13 Indoor Industrial -Dust and Drip-tight Intended for housing pilot devices such as limit switches, foot switches, pushbuttons, selector switches, pilot lights, etc. and to protect these devices from lint and dust, seepage, external condensation, and spraying of water, oil or coolant.
CSA 1 Indoor General purpose enclosure providing protection from accidental contact of personnel with enclosed equipment. CSA 2 Drip Resistant - Indoor Enclosure constructed to provide a degree of protection from dripping and light splashing of non-corrosive liquids and falling dirt. CSA 3 Rain-resistant - Indoor/Outdoor Indoor/Outdoor enclosure constructed to provide a degree of protection from rain, snow, and windblown dust. Undamaged by external ice formation. CSA 3R Rainproof - Indoor/Outdoor Same as CSA 3 with higher resistance to rain and snow. Also undamaged by external ice formation. CSA 4 Rainproof - Indoor/Outdoor Indoor/Outdoor enclosure constructed to provide a degree of protection from rain, snow, windblown dust, splashing and hose-directed water. Also undamaged by external ice formation. CSA 4X Corrosion-resistant - Indoor/Outdoor Same as CSA 4 enclosure with added resistance to corrosion. CSA 12 Indoor Industrial Constructed so as to provide a degree of protection from circulating dust, lint fibers, and flyings; dripping and light splashing of noncorosive liquids; not provided with knockouts. CSA 13 Indoor Industrtial Constructed so as to provide a degree of protection against circulating dust, lint fibers, and flyings; seepage and spraying of noncorrosive liquids including oils and coolants.
UL 50/UL 508 Type 1 Indoor Indoor enclosure providing a degree of protection from contact with enclosed equipment and from limited amounts of falling dirt. UL 50/UL 508 Type 2 Water-resistant - Indoor Enclosure resistant to limited amounts of falling water and dirt. UL 50/UL 508 Type 3 Outdoor Outdoor enclosure providing a degree of protection from windblown dust, rain, and sleet. Undamaged by external ice formation. UL 50/UL 508 Type 3R Rain-resistant - Outdoor Same as UL 50/UL 508 Type 3 also providing a degree of protection from falling rain and sleet. UL 50/UL 508 Type 4 Indoor/Outdoor Indoor/Outdoor enclosure providing protection from splashing or hose-directed water, rain and windblown dust. Undamaged by the formation of ice on the enclosure. UL 50/UL 508 Type 4X Indoor/Outdoor Indoor/Outdoor enclosure same as Type 4 with added resistance to corrosion.
UL 50/UL 508 Type 12 Indoor Industrial Indoor enclosure providing a degree of protection from dust, falling dirt, and dripping noncorrosive liquids. UL 50/UL 508 Type 13 Indoor Industrial Indoor enclosure providing a degree of protection form dust and spraying of water, oil and noncorrosive coolants.
Page 41
CHAPTER 8: Pressure Reducing Valves (PRVs)

SECTION I: OVERVIEW Maintaining a Constant System Pressure The discharge pressure for a booster system is dependent largely on the suction pressure, and to a lesser degree on the flow rate. These conditions can vary greatly during the normal, day-to-day operation of a system. A booster system must be able to deliver a reliable, constant system pressure in order to satisfy the requirements of a particular application. This is accomplished by regulating the discharge pressure of each pump using a pressure reducing valve, or PRV. The PRV reduces the system pressure according to the conditions at discharge to maintain a constant system pressure. The system is designed so that the discharge pressure from the individual pumps always exceeds the desired system pressure. This overage is then reduced to the desired system pressure by the PRV. The action of the PRV will account for variations in pump performance across the pump curve and for variations in the system supply (suction) pressure.
PRV Components The PRV can be broken down into two main assemblies: a) The main body valve assembly b) The pilot assembly
The dashed line seperates the internal main body valve and the external pilot assembly.
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The main body valve assembly is the portion of the PRV through which the main flow travels. The main body valve consists of the following parts and subassemblies: a) b) c) d) e) f) g) The valve cover The cover spring The main body diaphragm The valve stem The seal and retainer assembly The main body seat The strainer
(b)
(a) (c)
(d)
(f)
(e)
(g)
Main body valve components and subassemblies.
The pilot assembly controls the opening and closing of the main body valve. The main body valve is, in fact, slave to the pilot setting. Opening the pilot valve will open the main body valve. Closing the pilot will close the main body valve.
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The components of the pilot assembly are as follows: a) b) c) d) The pilot pressure reducing valve (with diaphragm) The in-line check valves The piping assembly The closing speed control
(c)
(d)
(b) (a)
(b)
Pilot assembly and components.
SECTION II: HOW the PRV WORKS To effectively regulate the system pressure, the PRV must change the amount of pressure reduction depending on the pressure of the incoming flow. This is accomplished by the opening and closing of the main body valve. As the pressure of the flow entering the PRV increases, the main body valve closes causing a greater reduction in the out-flow pressure. Conversely, as the in-flow pressure decreases, the main body valve opens causing a lesser reduction in the out-flow pressure.
Page 45
FLOW
OPENING CLOSING
Flow through the main body valve is controlled by varying the pressure in the pilot assembly. This is done by turning the set screw on the pilot pressure reducing valve. Closing the screw (as shown by the dark arrows) prevents flow through the top piloting tube. This causes pressure to build up on top of the diaphragm, closing the main valve. Opening the screw (as shown by the light arrows) increases flow through the top piloting tube. This reduces the pressure on top of the diaphragm causing the main valve to open.
The action of the main body valve is regulated by the piloting system. As the incoming pressure increases, so does the pressure in the pilot circuit. This pressure is transmitted to the top of the diaphragm forcing the valve closed. A reduction in pressure causes the reverse effect opening the valve. Why does the pilot win out over the main valve? The pressure above the diaphragm is exerted over an area 1.5 times greater than the seat area through which the main flow must travel. This area differential gives the pilot an advantage (a type of hydraulic leverage), enabling it to control the action of the main valve.
Pilot Pressure Diaphragm Area (Pilot Area)
Seat Area (Flow Area)
Flow Pressure
Fig.# 5: The pilot pressure wins out over the flow pressure due to hydraulic leverage advantage.
Page 46

SECTION III: COMMON PRV ADJUSTMENTS The performance of the PRVs in a booster are critical to the optimal performance of the entire system. Occasional adjustments and maintenance are required in order to keep the system running smoothly. Often, an improperly set or damaged PRV will show itself in the booster systems overall behavior. The symptoms of PRV problems are not difficult to recognize. PRVs sometimes will not close, will not open, or will not regulate the pressure at the set point. The causes of the symptoms can be more difficult to diagnose. In general, before you begin to dissasemble a PRV, it is advisible to first check that the problem is with the PRV. This section discusses some of the most common problems encountered with PRVs. When encountering PRV reguating problems, first check that the system around the PRV is running properly. During normal operation all isolation ball valves to and from the PRV should be open. Check that the closing speed control and pilot valves are not closed. You may then want to inspect the PRV for leaks and visible damage. Before begining the following procedures, close the isolation ball valves to the PRV in question. Stem Binding This is an easy test to perform before you fully dissasemble the PRV. Insert a 2 to 3 10-32 screw into the tapped stem at the centre of the main body cover. Using a set of pliers, pull the screw outwards. The stem should freely travel as you perform this action. Air in Control Circuit or Pilot Air in the PRV pilot assembly must be bled off at startup and can sometimes become a problem if the system is shut down for an extended period of time. To begin this procedure, open the isolation ball valves to the PRV. Carefully open the check valve cocks allowing some water to bleed out. This will vent any trapped air in the pilot piping and under the main body valve cover. Clogged Strainer The strainer can be removed from the main body valve after closing the PRV isolation ball valves. The strainer is mounted on a brass fitting just below the seat assembly. Remove this fitting and clean the strainer of any debris. Diaphragm Failure The two diaphragms of the PRV are subject to wear and occasionally require replacement. Main body diaphragm failure is characterized by the inability of the PRV to close. A ruptured main body diaphragm upsets the pressure balance inside the valve causing it to fly open. To replace a damaged diaphragm, remove the valve cover and the two nuts mounted on the stem. Pull away the diaphragm washer plate, and remove and replace the diaphragm. Pilot diaphragm failure is easier to diagnose. The pilot valve will leak water if the diaphragm is damaged. To replace, simply remove the four screws on the pilot cover being careful not to lose the spring and retainer. Remove and replace the diaphragm.
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Seal Failure Seal failure is characterized by failure of the PRV to close. Replacing the seal on a PRV is probably the most involved maintenance procedure you will be required to perform. The procedure is simple, but you must be careful to replace parts carefully on reassembly. Be especially careful not to damage the diaphragm and to replace both nuts on the stem. Remove the main body cover and diaphragm. Remove completely the stem and seal retainer assembly. The most common seal repair is replacement of the seat or the stem O-ring. You will see that the seal retainer has a top plate, the retainer, and a bottom plate, the Quad-Seal retainer plate. The Quad-Seal plate is fastened to the stem, but the retainer will come free. With a mallet made of a soft material, gently tap the top of the stem while holding the retainer. The plate will come free allowing you to remove and replace either of the O-rings. Tip: The seat O-rings are reversible. Each has two seal surfaces and can be reversed to provide double the life of an ordinary O-ring.
Page 48

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Pressure Booster Systems Designers Handbook

CHAPTER 1: The Domestic Pressure Booster System

Supply + Boost = System Pressure

Supply Pressure (from City)

Pressure Booster Systems Designers Handbook

Pressure Booster Systems Designers Handbook

CHAPTER 2: The Plumbing System

Pressure Booster Systems Designers Handbook

WATER SUPPLY FIXTURE UNITS - WSFU

4.0 1.0 4.0 1.5

3.5 0.5 2.5 1.0 4.0 1.5 0.5 0.75

2.5 1.0 1.5 2.0 1.0 2.0

2.5 1.0 1.0 1.0 0.5 2.0

2.5 2.5 5.0 3.0 7.0 4.0

2.5 2.5 5.0 3.0 7.0 4.0

2.5 2.5 5.0 5.5 8.0

Pressure Booster Systems Designers Handbook

Fixture Unit Chart

Total Fixture Units

Pressure Booster Systems Designers Handbook

Shut-off Pressure Design Condition

Shut-off Pressure Shut-off Condition

Shut-off Pressure Design Condition

Additional Pressures Dangerously High!

60 PSI Actual Suction Pressure 20 PSI Design Suction Pressure

Pressure Booster Systems Designers Handbook

Pressure Booster Systems Designers Handbook

Pressure Booster Systems Designers Handbook

CHAPTER 3: Pump Selection Considerations

Pressure Booster Systems Designers Handbook

CHAPTER 4: Drawdown Storage Tanks

Pressure Booster Systems Designers Handbook

Skid Mounted Tank

Pressure Booster Systems Designers Handbook

SECTION II: PIPING CONFIGURATIONS

Check valve holds against pressure backflow through pumps.

Water exits tank through same pipe

Tank Piping Schematic (Adjacent and Skid Mounted Tanks)

Pressure Booster Systems Designers Handbook

CHAPTER 5: Pump Staging for Energy Efficiency

Triplex Possible reason for choice

Pressure Booster Systems Designers Handbook

67% 50% 25%

Pressure Booster Systems Designers Handbook

Comsumption (in kWhrs)

Actual Consumption 33-67 Split

0 0h00 1h00 2h00 3h00 4h00 5h00 6h00 7h00

Pressure Booster Systems Designers Handbook

Pressure Booster Systems Designers Handbook

CHAPTER 6: Variable Speed Pressure Booster Systems Application and Design

Supply + Boost = System Pressure

Pressure Booster Systems Designers Handbook

3500 rpm Constant 1950 rpm Constant VFD Control Curve

0 0 20 40 60 80 100 120 140 160 180 200

E = (QPt/)constant speed - (QPt/)variable speed

Pressure Booster Systems Designers Handbook

E = (QPt/)constant speed - (QPt/)variable speed E = [(100gpm)(85psi)(2.31)(24hrs)/(85%)(65%)(3960)] - [(100gpm)(70psi)(2.31)(24hrs)/(85%)(65%)(97%)(3960)]