Next Generation Intelligent

Pumping Technology

Brent Ross – Director

Smith and Andersen Consulting

Engineering

Next Generation Intelligent Pumping Technology

 Toronto
Head office and
Manufacturing Facility

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Agenda

Reduce Energy and Cost with Modern Pumping Technology

Further reductions with parallel pumping operation and

appropriate redundancy

Save 40% in lifetime operating cost through pump connectivity

and active Performance Management

Discussion and close

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Traditional solutions create
a cost/efficiency dilemma

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Armstrong has resolved
the dilemma

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Discoveries of 18 years of practice

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Example: first-cost savings

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Opportunities in Fluid Flow

Integration of Components –
NOT Variable Speed Drives On Wall

Parallel Pumping

Redundancy – NOT DUTY STANDBY

Connections and Active Performance Management

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Next-level thinking delivers
unmatched efficiency

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Circa – 1950s through 1990s
- Constant speed pumping using 3-way valves

• At the time, energy costs were low

and the savings didn’t warrant the
added expense of variable speed
control
• 3-way valves installed at coils to
divert unnecessary flow volume
• Pumps operate at full speed and flow
• System mechanically throttled to
control system flow
• This is the base case used for later
energy savings comparisons

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Circa – 1990s to today …
Converting constant speed pumps to desired speed

• Variable speed controllers typically

mounted on walls close to the
constant speed pump

• VFD enables throttling valve to be

opened and pump speed reduced to
deliver the original system design
flow requirement

• Constant flow applications save

energy with variable speed

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Opportunities over drive on wall for pumping systems

• 2015 study by ACEEE.org concluded

• 60% of the ideal energy savings is
frequently missed
• 1990 strong step forward. But today
there are much better solutions
Are your variable speed pumping
applications delivering the
predicted savings? Improving
control to maximize results

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Facilities with drive on wall standards

• Drive standard addresses complexity and

reliability
• Efficient HVAC product with integrated
controls
• Cooling towers, Chillers, fans, circulators
and pumps
• Application specific controls

• Most efficient motor technology

cannot be driven by drives on wall
• Permanent magnet
• Synchronous reluctance
• Switch reluctance
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Wall-mounted drives

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Circa – 1990s to today?? …
Variable speed pumping – Wall-mounted vfd
with remote sensor and 2-way valve systems
• Variable speed controls become more popular
• Motors increasing in efficiency and insulation 0
quality
• Pumps selected as constant speed pumps,
designed for the specified flows and heads only
• Feedback sensors placed closer to the most
remote load coil
• If wall mounted drive is simply mounted on a
pump performance is the same
• If a sensor fails, or controls are not configured
correctly or bypassed, energy savings go back
to base case

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Typical locations for differential pressure sensors

Most Remote Load

Other Remote Load

Mechanical Room

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Locating the sensor in the mechanical
Room provides minimal turndown

Design Speed
Turndown

50% Load Speed

B A
Operating ‘Curve’

System A Design Point

Curve System
Curve
B ∆P Sensor Set-Point
50% Load Design Load

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 Significant turndown is possible with a ∆P sensor properly
located at the most remote load

Design Speed
Turndown

50% Load Speed

B
System A Design Point
Curve System
Curve
B ∆P Sensor Set-Point
50% Load Design Load
NOTE: Sensorless directly replicates control in a system with ONE system. In diverse systems multiple sensors are often used.
Sensorless does not directly replicate a a multi sensor systems. Designers however sometimes forgo the theoretical function of
multi sensors when they consider the inherent unreliability and opt to go sensorless instead.
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Design Envelope and sensorless control

• Pump quadratic speed control and demand

based operation
• Smaller motors selected in 25% of installations
• Integrated controller lowers motor losses which
increases motor efficiencies
• Actual pump flow readout value accuracy
of +/-5%
• Pump selections optimized for average load
against a system load profile

Armstrong Introduced Design

Envelope in 2004.

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2017 - Design Envelope Generation 5

• Advanced digital controls

(1 HP to 1250 HP)
• Excellent PUMP User interface
• DE permanent magnet motors
• Design Envelope hydraulic
designs
• Integrated Parallel Pumping

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Simple intuitive set up specific for pumps

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Customer HVAC system concerns

Differential pressure sensors issues

• Sensor acquisition, installation and controls wiring

• Incorrectly installed sensors
• Sensor installed in the wrong location
• Incorrect range for pressure or setting
• Incorrectly set
• Easily damaged during construction
• Subject to setting drift
• Subject to site shortages

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Control with sensor vs sensorless control
PROGRAM
MAP

Control with Sensor Sensorless control

• Changes in system read by DP sensor
• Sensor converts to signal (4-20mA)
• VFD reads signal and modulates speed
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• Changes in system = motor amp draw change
• DE pump compares amp draw to its
Sensorless program map
• DE pump slows down or speeds up based on
program map
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Sensorless Control
H 60 Hz

53 Hz

40 Hz

Control Curve

20 Hz

Q
P P

60Hz
53 Hz

40 Hz
Power – Flow Curve

20 Hz
Power – Speed Curve

Q 20 Hz 40 Hz 53 Hz 60Hz S
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An integrated approach to reducing system cost
Sensorless control
No pressure
sensors
necessary

$2000 Savings over installed sensor

$600 Commissioning cost savings

BMS Savings with Parallel Sensorless

49% Energy savings over mechanical room sensor

Mechanical room

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Design Envelope Pump Sensorless Control

Quadratic, constant flow and constant pressure available

Head

Flow

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Design Envelope pump integrated controls

2 Way Bypass Valve Control

X Maximum Flow Control

Minimum Flow Control 2 Zone Control

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Power of Integration

RFI
EMI

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Parrallel

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Parallel redundancy – turndown accuracy

Turndown – See ASHRAE 90.1

• Percentage of design flow at which the flow is stable and can be accurately measured

1 pump Turndown 2-pump Turndown

Can operate at high
30% of BEP flow
30% of BEP flow efficiencies over load profile
Eff Eff

1P Eff 2P Eff

1P Eff
Turndown
24% / 4:1 Turndown
12% / 8:1

24% 50% Flow 12% 50% 100% Flow

80% 100%
40% 80%

Flow Accuracy and Stability

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An integrated approach to reducing system cost
Parallel Sensorless Pump Control – staging methodology
1P EFFY 2P EFFY 3P EFFY 100%

80%

EFFICIENCY

POWER
HEAD

60%

40%

Armstrong
Best 20%
Efficiency
Staging 0%
FLOW
1P EFFY 2P EFFY 3P EFFY 100%

80%

EFFICIENCY

POWER
HEAD

60%

40%

Speed 20%
Based
Staging 0%
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Parallel Sensorless Pump Control – Performance benefits

= Areas of
highest
1P EFFY 2P EFFY 3P EFFY
inefficiency

Energy Savings:
3 x 40HP Pumps

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

Best Efficiency Staging

SPEED BASED ~ $20,092
STAGING
34% Saving

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

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Redundancy and System Resilience

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Now 90 Percent

• Parallel multiple pump selections for

lower operating costs and turndown
control

• Appropriate redundancy

• Best Efficiency Staging through

Parallel Sensorless Pump Control

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Redundancy implications
Impact on cooling or heating output Cooling coil capacity

P%

98% 100%
95% = Heating
= Cooling
Percent of Emitted Power

~80% of design flow still results in

approx. 95% or greater heating /
cooling coil emission

Minimal impact to occupant comfort!

Maximum rise of 1.5 degrees F on

design day with minimal effect on
Q%
0 80% 100% Relative humidity.
Percent of Full Flow
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Cost / Carbon footprint – sizing for 100% duty/standby vs 2 x 50%
in parallel

20hp 10hp

20hp 10hp

20hp 20hp 10hp 10hp

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Level of redundancy by building type

• Mission Critical – 100% Flow Redundancy (2 x100% split)

• Critical Care Facilities / Blood Banks / Labs R&D / Hospitals
• Data Centers

• High Comfort Sensitivity Facilities - 85% Flow Redundancy (2 x 70% split)

• Hotels / Offices / Commercial / Mixed-use
• Outpatient Clinics / Universities / College campus

• Generic Duty unit(s) - 70% Flow Redundancy (2 x50% split)

• Schools / Apartments / Condos / Religious Institutions
• Factories / Warehouses

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Electrical Bypasses
• History - In the 1980’s VFD’s had OVER 100% warranty rate
Electrical bypass’ needed!
• Variable speed electronics warranty today < .25%
Bypasses are less reliable than Variable Speed Electronics
• Bypasses preclude use of load limiting logic and escape of 60
hz 25% of time a larger motor, VFD electronics are needed
due to bypasses, can’t use latest motor (permanent magnet etc.)
technologies.
• In the 100 chiller plants Armstrong monitors globally, 50% at
any point in time find pumps in manual or bypass average 3
months to rectify increased energy consumption
Use of bypasses today very costly! Armstrong recommends
careful analysis of true redundancy needs, in rare case more
redundancy needed put in another pump or convert single to
dual pumps
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700,000 sq/ft Commercial Building
• 360 Heat pumps serviced via two central loops
• Heat pumps reject heat to and take heat from central
loops
• Water circulated in each central loop with 3 x 30 /
40hp pumps
• Loops operating about twice the required flow AND
twice the head with constant speed pumps
• 3 x 20/30 hp (same performance capability) Design
Envelope pumps and control modifications
produced
• 84% energy savings in one pump bank and 93% energy
savings in the other
• Equating to 812,330 kwhr annually @ $.13 / kwhr =
$115,603 per year.
• Payback < 1 year.

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 Vertical Inline Pump Retrofit kit to demand-based
control

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 • Improved on-board diagnostics and
trending

• Active Performance Management

• Permanent Energy abatement

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The intelligent
pump

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Pump Manager: An Active Performance Management Service For 5th
Generation Pumping Technology

A cloud based Performance Management

service.

Industry leading analytics and pump

specific insights.

Enhanced reliability and sustained

optimal performance

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 Benefits

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Features

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Parrallel

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Pumping System Technology 53
Traditional approach to system upgrade

Chiller first

45+ month
system
retrofit cycle

Lock in risk

Risk of energy drift

Tied-up capital

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The system upgrade map - possible path
pump + optimization + your plant

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Energy upgrade cash flow

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Fluid Flow and Design Envelope Technology

1. Discover your 65% savings behind the VFD on the wall. Integrate
your components with us.

2. Discover the new standard of parallel pumping – Design Envelope

Sensorless and Tango enabled

3. Say goodbye to duty standby Hello to 35% savings through a

new paradigm of redundancy

4. Unleash Active Performance Management and discover up to 40%

permanent cost abatement

5. For HVAC energy upgrades start with pumps optimization

chillers / cooling towers

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Close

Comments
and
Questions?

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