How to achieve more energy efficiency

from your chilled water system?

Presented by Supriyadi PT. Grundfos Pompa

Chilled Water Distributed Pumps

MAGNA3

TPE3

MAGNA3
PERFORMANCE RANGE

TPE3

 Distributed Pumping Concept

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

The cost of running pumps

5%

95%

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

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

Calculating Pump Head Losses

Hydraulic Gradient

Reducing Pump Head Losses

Calculating Pump Head Losses

Hydraulic Gradient

Chilled Water System- Water Cooled

Primary Pumping Design

High Energy Consumption !

Variable vs Constant Head Loss

Supply
C
H
I
L
L
E
R

C
H
I
L
L
E
R

C
H
I
L
L
E
R

Pump
Controller

Adjustable Freqy. Drives

Return

Chilled Water System- Water Cooled

Primary & secondary Pumping Design

Pump Energy Saving Basic !

~ with VFD Secondary Pump

Any Other Method To Further

Save Pump Energy ???
VFD

SECONDARY
PUMP
PRIMARY
PUMP

Variable vs Constant Head Loss

Supply
C
H
I
L
L
E
R

C
H
I
L
L
E
R

C
H
I
L
L
E
R

Pump
Controller

Adjustable Freqy. Drives

Return

Conventional Primary Direct Pumping System

DPT
M

VSD

Chiller
Variable Speed Primary Pump

Distributed Pumping Concept A No-Brake Solution

VSD

VSD

VSD

VSD

VSD

VSD

Chiller
Primary Pump

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

Energy Efficient Distribution

1) Design high T Chilled water System
Btu= 500xQxT increase T, reduce Q
BHp=QxH/(3960x%) reduce Q, reduce pump BHp

Similar Cooling Capacity

T = 10F
12000Btu=500xQx10
Q=2.4 usgpm

T = 16F
12000Btu=500xQx16
Q=1.5 usgpm

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

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

Energy Efficient Distribution

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
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

Cooling Coil 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

DPT
P 4m

P 3m

P 2m
P 4m

P 4m

P 4m

P 4m

P 3m

P 2m
P 3m

Pump Power Calculated = 19.6kW

P 2m
P 3m

P 2m
P 3m

P 2m

M
P 10m
1000 USGPM, 416 TR

Chiller
Variable Speed Primary Pump

Total Pump Head: 27m

Efficiency of Primary Pump : 85%

Distributed Pumping System Pumping Energy

Efficiency of Distributed Pumps : 70%
P 3m
Head for Pump 5-1: 13m
200 USGPM

P 2m

P 3m
200 USGPM

Pump Power Pump 5-1: 2.298 kW

Head for Pump 4-1: 11m

P 2m

Pump Power Pump 4-1: 1.945 kW

P 3m

Total Pump Power Calculated = 15.2kW

Head for Pump 3-1: 9m

200 USGPM

Energy Savings of 22%

P 2m

P 3m

at design flow

48% Savings

200 USGPM

at 50% flow

Head for Pump 2-1: 7m

Pump Power Pump 2-1: 1.237 kW
P 2m

P 3m
200 USGPM

Pump Power Pump 3-1: 1.591 kW

Head for Pump 1-1: 5m

P 2m

Pump Power Pump 1-1: 0.884 kW

P 10m

Primary Pump

1000 USGPM

Head For Primary Pump: 10m

Chiller

Efficiency of Primary Pump : 85%

Pump Power Pump 1-1: 7.281 kW

Chilled Water System- Water Cooled

Primary Pumping Design

Equipment/piping

Pressure drop

Chiller
Piping(10 flr x 13 ft/flr x 2 way x 4/100)
Fitting & valve (20% of piping)
AHU
Modulating valve
Total

= 25
= 10.4 ft
= 2.1 ft
= 20 ft
= 30 ft..
= 87.5 ft

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

Chilled Water System- Water Cooled

Primary Pumping Design

Equipment/piping
Chiller
Piping(10 flr x 13 ft/flr x 2 way x 3/100)
Fitting & valve(20% of piping)
Total (A)

Pressure drop
= 25
= 10.4 ft
= 2.1 ft
= 37.5 ft

AHU
Modulating valve
Total (B)

= 10 ft
= 0 ft.
= 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)
0.2 Hp x 10 AHU

= 0.36 Hp
= 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.

Manual balancing requires extra valves

Extra large
expensive valves are
required to attempt
to minimize readjustments.
Branches
Risers
Mains

Control For Conventional System

DDC

Return Air Temperature

Building Management System

T
M

CHWR

CHWS

Control For Distributed Pumping

- maintaining constant T for a healthy system

Cooling load,
CHW Flow Rate

chilled water T T

Building Management System

DDC
CHWR

Speed

CHWS

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

Compact stator

Composite rotor can

Patented differential
pressure sensor

Neodymium
technology rotor

New generation inline Pumps TPE3

Neck ring

Sensor and cable

Shaft seal

Impeller

Shaft

Pump housing

nut
Clamp

Bushing

Motor stool
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

BMS Integration
The MAGNA3 can be seamlessly
integrated to any BMS System in
your facility today.

BMS Integration

BMS

BMS Gateway

Heat Energy Meter

INTELLIGENCE IN THE MAGNA3

The Magna3 has an

integrated BTU meter that
measures heat energy
consumption without the
use of additional
instruments.

Before

After

Flow Measurement
INTELLIGENCE IN THE MAGNA3

The Magna3 has a flow

measurement accuracy of
1% at design flow (blue
region).

Magna3 40-100

Flow Measurement
INTELLIGENCE IN THE MAGNA3

Mechanics

Accuracy

Installation
Requirements

Electromagnetic Flowmeter
Determine the fluid velocity by
induced voltage
Highly dependant on
compliance to installation
requirements.
Typical catalog quote accuracy
0.5% of operating range (9 to 10
m/s)
Accuracy @ pipe actual flow
rate 2 m/s : 1.8 to 2.25%
Min 5D upstream & 3D
downstream to ensure any
accuracy

Differential
No Requirements
Pressure Required

Dynamic Balancing Valve

Determine flow rate by
calibrated opening (orifices)

Magna3
Determine flow rate by
pressure & pump speed

Independent of installation

1% at design flow

2% of valve maximum flow rate

at 2 m/s

No specific requirements

None

Up to 80 kPa for valve max flow

None
rate of 2 m/s

FLOWLIMIT
INTELLIGENCE IN THE MAGNA3

FLOWLIMIT control function makes

it possible to set a maximum flow
limit for the pump

Before

After

Input/output
INTELLIGENCE IN THE MAGNA3

The Magna3 has integrated in- and

outputs points for sensors and
communication to BMS.
The no. of I/O points are:
1 x analogue input (0-10V/4-20 mA)
2 x relay outputs
Analog input

3 x digital inputs
Relay output
Digital input

Optimization
INTELLIGENCE IN THE MAGNA3

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
INTELLIGENCE IN THE MAGNA3

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

Communication

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

Status : flow and head

Magna 3

Sample of Motorized Control Valve

Running Power

Thank for Listening