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Variable Volume Pumping Fundamentals Part I

Variable Volume Pumping Fundamentals Part I Es el objetivo del ingeniero de climatizacin para disear el sistema ms rentable de bombeo, mientras que satisfacer las necesidades del cliente. Primaria-secundaria de bombeo es una herramienta de los ingenieros de HVAC han estado utilizando durante casi 50 aos para lograr este objetivo.

ASHRAE / IES Design Standard 90.1-1989-Diseo eficiente de la energa de los nuevos edificios de baja altura excepcin de edificios residenciales, requiere "todos los sistemas de bombeo con las vlvulas abiertas y cerradas de modulacin o de paso que tienen potencia total del sistema de bomba de 10 debe ser capaz de fluir en un 50 por ciento del valor de diseo o menos. "Manual de la Norma 90.1-1989 del usuario" recomienda altamente " bombeo primaria-secundario para" los sistemas con grandes, alta cada de presin para sistemas de distribucin, tales como aquellos que sirven a las universidades y aeropuertos ". El bombeo Primaria-secundario (fig. 1) proporciona los medios para el bombeo de volumen constante de las bombas de potencia primaria bajos a travs del Chiller. Estas bombas son de menor potencia que las bombas secundarias, ya que slo tienen que superar la prdida por friccin asociada con el chiller, tuberas y vlvulas en el circuito primario. Las bombas de chillers estn equilibradas al caudal de diseo. Impulsores de la bomba deben ser recortados para minimizar la cada de presin a travs de la vlvula de la descarga de la bomba. Esta es una medida de ahorro de energa importante.

Las bombas secundarias son de ms altos caballos de fuerza, ya que tiene que superar la prdida por friccin asociada con el bucle secundario de distribucin de tuberas, conexiones, vlvulas, serpentines, etc Estas bombas funcionan en el modo ahorro de energa de volumen variable. Dependiendo de la rentabilidad de la inversin, las bombas secundarias o bien permanecen a velocidad constante y montar su curva caracterstica de capacidad - altura, o el diseador puede incorporar los convertidores de frecuencia para ahorrar energa de bombeo adicional (Fig. 2). Hay tres reas crticas de diseo que deben ser considerados para cualquier sistema de volumen variable de bombeo: La tubera comn Secuenciacin de los Chiller Vlvulas de control y actuadores Diseo de la tubera comn El diseo de la tubera comn (fig. 3) es crtico para el funcionamiento de un sistema primariosecundario. La funcin de la tubera comn es desacoplar hidrulicamente las bombas primarias y secundarias, mientras que todava proporciona interaccin trmica. Para asegurar el funcionamiento adecuado del sistema, los criterios comunes de tubos de diseo son:

La cada de presin mxima en la tubera comn no exceder de 1,5 Ft.

Establecer la cada de presin en la tubera comn asumiendo el flujo de la bomba ms grande del Chiller est pasando a travs de la tubera comn. La cada de presin resultante no debe exceder de 1,5 pies Esta es la base del bombeo primario-secundario. Superior prdida por friccin en el comn tiende a hacer que las bombas primarias y secundarias actuen en serie, resultando en un flujo inducido en el sistema. (Esta incorpora un factor de seguridad.) Tpicamente, Tpicamente, un Chiller es usualmente secuenciado encendido o apagado de por la mitad del flujo de la bomba ms grande. Por simplicidad de diseo e instalacin, la tubera comn es a menudo el mismo dimetro que la tubera de distribucin.

Mantener tres dimetros de tubo de separacin entre la T de suministro secundaria y la T secundaria retorno.

Una tubera comn de esta longitud es ms que suficiente para eliminar la mezcla debido a la velocidad de retorno excesiva en la tubera de retorno secundario. Tubos comunes de mayor longitud pueden resultar en una cada de presin excesiva superior a 1,5 ft, con resultados como los descritos anteriormente.

Bajo ninguna circunstancia una vlvula de retencin ser instalada a una tubera comn.

La adicin de una vlvula de retencin se traducir en las bombas primarias y secundarias que actan en serie cuando secundaria (distribucin) de flujo excede primario (produccin) de flujo. El aumento de la demanda resulta en un aumento en el flujo a travs del enfriador que puede conducir a mayores temperaturas en la descarga enfriadores y la erosin tubo enfriador. Ms detalles sobre este tema se discute ms adelante en la seccin de la secuencia de la enfriadora.

Otros trminos se usan indistintamente cuando se habla de bombeo primario-secundario.

El sistema primario tambin se conoce como el sistema de la produccin-lugar donde se produce el agua fra o caliente. El sistema secundario tambin se denomina el sistema de distribucin debido a que su propsito es transportar el agua fra y caliente desde y hacia la carga (s). La tubera comn tambin se conoce como un desacoplador. Esta tubera comn tanto a los sistemas primarios y secundarios, proporciona la separacin hidrulica entre los dos. Chiller sequencing Distribution flow equals production flowAlthough this flow condition rarely occurs, we will observe the flow pattern of this scenario (Fig. 4). The chiller is supplying 1500 gpm of 45 F water to the load system. The two-way valves in the secondary are responding to conditions equal to 1500 gpm x 10 F Delta T x 500 = 7.5 MBtuh or 625 tons. The two-way valves, coils, and associated piping represent a pressure drop of 100 ft. The secondary pump is riding its curve, producing the required 1500 gpm at 100 ft of head. Because the load is equal to 625 tons, the return water temperature to the chiller is 55 F at a flow rate of 1500 gpm. The thermal balance is complete. There is no flow in the common pipe. Secuenciacin de los Chillers

La Secuencia apropiada de los Chillers juega un papel importante en el rendimiento global de un sistema primario-secundario de bombeo. El operador del sistema debe reconocer las tres condiciones de flujo que pueden ocurrir. Estos son: Distribucin (secundaria), el flujo es igual a la produccin (primaria) de flujo. Distribucin de flujo es mayor que el flujo de produccin. Flujo de produccin es mayor que el flujo de distribucin. Distribucin de flujo es igual a la produccin de flujo. Aunque la produccin de esta condicin de flujo rara vez ocurre, observaremos el patrn de flujo de este escenario (fig. 4). El Chiller est suministrando 1500 gpm de agua a 45 F para el sistema de carga. Las vlvulas de dos vas en el secundario estn respondiendo a la igualdad de condiciones a 1500 gpm x 10 F Delta T x 500 = 7.5 MBtuh o 625 toneladas. Las vlvulas de dos vas, el serpentn, con su correspondiente tubera representan una prdida de carga de 100 pies. La bomba secundaria est montando su curva, la produccin requerida es 1500 gpm a 100 pies de la cabeza. Debido a que la carga es igual a 625 toneladas, la temperatura del agua de retorno a la enfriadora es 55 F a un caudal de 1500 gpm. El equilibrio trmico es completa. No hay flujo en la tubera comn.

The remainder of the time of the secondary or load flow will be greater or less than the primary flow. The moment the load increases in the space, the two-way valves begin modulating to a more open position and deliver additional chilled water to satisfy the additional load. When this occurs, the pressure and flow relationship changes such that the distribution flow is greater than the production flow (Fig. 5). El resto del tiempo del flujo secundario o de la carga ser mayor o menor que el flujo principal. En el momento en que aumenta la carga en el espacio, las vlvulas de dos vas comienza la modulacin a una posicin ms abierta y entrega agua enfriada adicional para satisfacer la carga adicional. Cuando esto ocurre, la relacin cambia la presin y el flujo de tal manera que el flujo de distribucin es mayor que el flujo de produccin (Fig. 5).

Distribution flow greater than production flowWith this condition, the flow rate through the chiller is 1500 gpm at 45 F. Because the flow rate is fixed at 1500 gpm, the pressure drop in the primary loop is constant. As the load increases in the secondary and the two-way valves modulate open in response, the secondary pumps run out on their curves to provide additional flow. As the secondary pumps run out on their curves corresponding to the reduced pressure, flow increases to the required 2000 gpm. If 2000 gpm is flowing into the secondary, 2000 gpm must return from the secondary. The balanced chillers will only accept 1500 gpm. To balance the mass flow, the excess 500 gpm must run through the common pipe. The temperature of the 500 gpm in the common pipe is 55 F. This blends with the 1500 gpm of 45 F supply water, resulting in 2000 gpm of 47.5 F blended supply water. Whenever the flow is greater in the distribution loop than in the production loop, the excess flow in the common pipe is in the direction towards the secondary pumps. The result will always be a blending of the return water with the supply water at a temperature higher than what the chiller produces. What will happen to the temperature control? A higher supply water temperature could mean a loss of humidity control in the zones. Higher supply water temperatures must be considered during the coil selection process. Distribucin de flujo mayor que la produccin de flujo Con esta condicin, la velocidad de flujo a travs del enfriador es 1500 gpm a 45 F. Debido a que el caudal se fija en 1500 gpm, la cada de presin en el lazo primario es constante. A medida que aumenta la carga en el secundario y vlvulas la forma de dos modular abierta en respuesta, las bombas secundarias agotado en sus curvas para proporcionar un flujo adicional. Como las bombas secundarias agotado en sus curvas correspondientes a la presin reducida, aumenta el flujo a la requerida 2000 gpm. Si el gpm 2000 est fluyendo en la secundaria, gpm 2000 debe regresar de la secundaria. Los enfriadores de equilibrio slo aceptar 1,500 gpm. Para equilibrar el flujo de masas, el exceso de 500 gpm debe ejecutar a travs de la tubera comn. La temperatura de la gpm 500 en la tubera comn es 55 F. Este mezclas con el gpm 1500 de 45 de suministro de agua F, resultando en gpm de 47,5 F de suministro de agua mezclada 2000. Siempre que el flujo es mayor en el circuito de distribucin que en el bucle de produccin, el exceso de flujo en la tubera comn es en la direccin hacia las bombas secundarias. El resultado ser siempre una mezcla del agua de retorno con el suministro de agua a una temperatura superior a lo que produce la enfriadora. Qu pasar con el control de temperatura? Una temperatura mayor aporte de agua podra significar una prdida de control de la humedad en las zonas. Las temperaturas ms altas de suministro de agua deben ser considerados durante el proceso de seleccin de la bobina.

Other options can be considered. For example, chiller temperature reset can be employed. Within the limits of the type of machine, chiller temperatures can be reset to a lower temperature to compensate for the increased load and secondary flows. In essence, more capacity is provided at a lower operating efficiency. The increase in cost of chiller operation due to the lowering of the chiller supply temperature can range from 1 to 3 percent per degree of reset. This is a very desirable alternative, especially when large chillers are in use. The longer the start of a lag chiller can be delayed, the better it will perform when it is finally brought on line. If a small portion of the load requires a fixed temperature, a small chiller in series with the load may also be considered. Production flow greater than distribution When incremental chiller capacity is added, the third flow condition occurs (Fig. 6). The flow rates through the chillers are again fixed, this time at 3000 gpm. The new load is 875 tons. As we are again seeing a 45 F supply water temperature and a 55 F return water temperature, the flow rate for the secondary pump is 2100 gpm. With 2100 gpm delivered to the secondary and 3000 gpm being pumped in the primary loop, there is an excess flow of 900 gpm. The 900 gpm excess must flow through the common pipe at the chilled water supply temperature of 45 F. The 900 gpm common flow blends with the 2100 gpm secondary chilled water return to produce 3000 gpm at a reduced entering chilled water temperature of 52 F.

All chilled water returning to the chilled water plant is blended prior to reaching the chillers. All of the chillers on line will therefore be receiving the same temperature water at their return. When the system is piped in this manner, the chillers will always be equally loaded. Furthermore, the chillers will always be subjected to their design flow at an equal temperature. Because the chillers are receiving their design flow rate at 52 F rather than the design temperature of 55 F, the chillers will be unloaded at the ratio of:

When piped with a common, the flow through the chillers is a constant. In our example, the two steps are either 50 percent flow (1500 gpm) or 100 percent flow (3000 gpm). The secondary flow is very close to a linear function. As the two-way valves modulate in response to a varying load, the flow follows directly. The more chillers in the plant, the smaller the steps. If we incorporate chillers in a variety of sizes, the incremental steps

are smaller. The additional chillers and variety of chiller sizes can produce a curve that is nearly linear. When the chiller plant is designed to produce a near-linear flow function, the supply temperature rises, the secondary is minimized, and the increased supply water temperature lasts for a shorter duration. This is a very critical factor in design regions where humidity control is a concern. Chiller sequencing can be as simple as manually turning on and off a second chiller. It can also become complex when multiple chillers of different sizes, types, and efficiency are installed. The chiller manufacturer is usually best suited to provide the information and instrumentation to effectively stage and de-stage its product. Conceptually, the designer needs to determine the best combination of chillers that will meet the flow demand. This is often done by calculating the Btuh consumed (Fig. 7). Instrumentation must be provided to determine: Secondary supply water temperature, Ts-s Secondary return water temperature, Ts-r Secondary flow, Fs

The amount of cooling Btuh produced is also valuable information. The necessary instrumentation is: n Primary supply water temperature (chiller leaving), T p-s n Primary return water temperature (chiller entering), Tp-r Primary flow (chiller flow), F p An algorithm is then prepared, which utilizes the best combination of chillers for the actual load. The measurement of flow and direction in the common pipe does not provide the operator with enough information to determine the time of sequencing. The same can be said for the measurement of flow in the secondary system. Control Valves and Actuators Control valves are a critical part of the variable volume hydronic system. The control valves functions are to vary flow properly through the water coil in response to a variety of building load conditions. Because of their critical nature, great care must be taken when selecting control valves so they perform properly. Undersized valves may provide insufficient capacity while oversized valves provide poor control. Equal percentage type valves are typically applied to cooling and heating coils because of their favorable flow characteristic. They provide a high degree of control accuracy with wide variations in pressures, flow rates, loads, and other variables. When combined with the heat transfer characteristic of a cooling coil, the change in stem position almost provides a nearly linear change in heat transfer if an equal percentage control valve is used.

Knowing the maximum differential pressure across the valve at any flow is an important criterion for valve selection for two reasons (Fig. 7): Choosing the appropriate actuator Avoiding valve noise and cavitation in valves and piping In variable volume systems, the selected valve actuator must be capable of closing the valve against the maximum pump head pressure (Fig. 8). In variable volume closed loop systems, all loads could be reduced causing the pump to ride back on the pump curve. As the pump rides back on the curve, the head being produced by the pump increases. The control valve actuator must be strong enough to continue modulating the valve closed as the pressure increases. In the worst case, this could be the shutoff pressure being produced by the pump. Improper actuator sizing may result in some water passing through the valve and coil, which add to low return water temperatures.

Excessive valve noise and valve cavitation are caused by high liquid velocities. As water passes through a valve, it is accelerated. With the increase in velocity pressure, the static pressure falls. If it drops below the vapor pressure, bubbles form. Then immediately downstream of the valve, velocity decreases and the static pressure increases, causing the bubbles to collapse. The result is noise coupled with excessive wear in the valve body, throttling mechanisms, and sometimes in the downstream piping where this takes place. When variable speed secondary pumping is employed, valves are normally subjected to less differential pressure. In this mode, the pump follows the characteristic control curve ential pressure when conditions are at less than maximum design. Care must still be taken if an acrossthe-line (ATL) adjustable frequency drive bypass (electrical bypass) is used. When the system functions in the ATL mode, the pump acts like a constant-speed pump. It is now following the pump flow-head curve at a much higher pressure. The designer may overlook this condition. Under low flow conditions, the valves may lift up as described earlier. If the selected actuators have inadequate holding power at the higher head shut-off condition, the valves may lift up as previously described. Three-way valves have little use in variable volume pumping systems. Three-way valves bypass unused chilled water past the load; this results in multiple problems. Bypassed water lowers the return water temperature and increases flow rates. As a result, additional chillers and pumps are brought on-line to provide flow, rather than to control the cooling load. A circumstance where three-way valves can be used (carefully) in the system is to maintain minimum flow as a means of pump protection. As a rule of thumb, the Hydraulic Institute and ITT Fluid Handling recommend a minimum flow rate of 20 percent of the best efficiency point flow rate. To limit the radial and axial loads and shaft deflection, our recommendation is to maintain a minimum flow rate of 25 percent of the best efficiency point flow rate.

The Hydraulic Institute and ITT Fluid Handling also recommend limiting the temperature rise of the fluid flowing through the pump to 15 F. (This is not to be confused with the system temperature rise.) When a pump is operating in a low flow condition, the temperature rise occurs in a small volume of water. If an insufficient volume of water flows through a pump, the inefficiency of the pump is converted to heat. In time, the heat build-up can cause the fluid to vaporize and eventually result in To calculate the flow rate for a 15 F temperature rise use the following equation:

When careful attention is given to these fundamentals, energy savings will be achieved and design system Delta T will be achieved. As system characteristics change due to load changes, the aging of the piping and coils, or even as coils get dirty, system Delta T may suffer. There is no substitute for knowledgeable operators and proper maintenance schedules. The adjustment of thermostats and the lowering of supply air temperatures will only add to the inefficiency. Unless problems are cured, only patches can be applied to treat symptoms. Fixes consume additional energy. The only way to keep a properly designed HVAC system operating efficiently is to maintain it in the appropriate manner. Conclusion To optimize system performance and design flexibility, the designer must select the type of distribution piping and pumping configuration that will best meet the needs of the client. The following are the four basic types of pumping systems in use today. Primary-secondary Primary-secondary-tertiary Primary-secondary zone Primary variable speed These pumping methods will be discussed in the next issue of Tech Talk. This article was originally published in the August 1998 issue of Heating/Piping/Air Conditioning magazine. Reprinted from TechTalk January 1999 Copyright 1999 by ITT Industries

To optimize system performance, the designer has a number of variations of basic primarysecondary pumping to explore:

Pumping Fundamentals In the previous article Variable Volume Pumping Fundamentals, the concept of variable volume pumping is thoroughly developed. The example cited is a primary-secondary pumping system. Primary-secondary pumping configurations are successfully applied by thousands worldwide and is the standard approach for many design engineers. To optimize system perfor-mance, the designer has a number of variations of basic primary-secondary pumping to explore. Primary-secondary zone pumping systems Primary-secondary-tertiary pumping systems Primary variable speed pumping systems

1. Primary-secondary zone pumping. Each type of pumping system configuration has distinct advantages for the user or operator. There are also cautions to consider. Fundamental to all of these configurations is sound design principles. Without the proper application of the basics, the most sophisticated systems will not operate effectively. Primary-secondary zone pumping systems A variation of the traditional primary-secondary pumping scheme is primary-secondary zone pumping (Fig. 1). This configuration is also referred to as distributive pumping. The principles of primary-secondary pumping still apply. The difference in this design is that the main distribution pump is eliminated in favor of multiple zone or building pumps. Using this approach and under the right conditions, pumping horsepower can be saved initially and in the future. Zones close to the chiller plant are not overheaded (over-pressurized) to meet the demands of the zones farther downstream. In large applications, pressure may also be reduced-saving pipe, valve, coil, and tank first cost. Gil Carlson of Bell & Gossett demonstrated the value of primary-secondary zone control in the early 1960s. Design considerations Each zone pump is decoupled from the chiller pumps through a common pipe. They are, however, not decoupled from each other. Essentially, they operate in parallel. The suction and discharge of the pumps are connected through shared supply and return piping. A very small pressure drop must be maintained in the pipe shared by these pumps. This pipe includes the common pipe and the shared supply and return header (Fig. 2). The designer must be extremely

careful with the selection of the pumps and the balancing of each zone. Pumps should have the same or similar pump curves. Pipe sizing Friction loss in the shared piping dramatically effects the performance of zone pumped systems. Per ASHRAEs recommendation, friction loss no greater than 4 per 100 ft. of equivalent pipe should be followed. Friction loss must be calcu-lated at the maximum flow rate expected in the future. Pump selection The action of pumps in the downstream zones (Pumps B and C) will affect the pump in Zone A (and vice versa), unless the distribution pipe has a very small pressure drop due to a large diameter or a very short length as shown in Fig. 2. Friction loss in the piping is based on a squared law function. The friction loss assigned to Zone Pump A must be based on the total flow in the shared pipe. Zone Pump A must overcome the added pressure drop in the shared pipe based on all of the pumps in full operation.

2. Shared piping Future loads As loads are added in the zones, pressure drops increase in the zone piping as well as in the shared piping. Existing pumps may need to be increased in size, be replaced to meet the new resistance, or sized larger in anticipation of future conditions. Future zones As with future load changes, future zone requirements must also be considered. Pumps must be selected with future zone character-istics in mind. The addition of an unexpected zone may require the replacement or modification of all or some of the existing zone pumps. If future zone requirements are known, the existing pumps can be selected large enough to meet future requirements. Pumping compatibility The square law relationship between the piping system and the pumps is very important, especially when applying adjustable frequency drives to zone pumping. When the decision is made to apply zone pumping, the decision must also be made whether all of the pumps will be constant speed or use variable speed. Since the zone pumps are operating in parallel, the pumps operating curves must be compatible. The point of operation of down stream pumps will affect the performance of the upstream pumps and vice versa. Downstream users

Since each zone pump must be capable of providing enough differential pressure to transport water from the chiller plant to the loads and back to the chiller plant, each successive zone pump must be larger in horsepower even if the zone flow rates and pressure drops are similar. In a districttype system, the customer at the end of the distribution system can require pumps of signifi-cantly greater horsepower than those close to the plant. Controls Each zone operates independently and requires its own variable speed controls. It is not recommended to mix constant speed and variable speed zones in the same system. Balance Balance is a critical factor in the design and operation of a zone-pumped system. If the system is not properly balanced, the return distribution pipe may be over-pressurized. Over-pressurization will compound the system problems. Valves can lift off their seats, resulting in hunting and poor temperature control. Primary-secondary- tertiary (tertiary) pumping systems. Another variation of primary-secondary pumping is tertiary pumping (Fig. 3). Secondary pumps distribute the chilled water from the central plant to the connected buildings or zones. Individual buildings or zones are decoupled from the distribution loop through a tertiary bridge. A major advantage of tertiary pumping is that the individual zones are hydraulically and thermally decoupled.

3. Primary-secondary-tertiary pumping. This allows the designer some flexibility to control each zone independently, relative to differential pressure and temperature. Zones may be a collection of coils, air handlers, or entire buildings. This advantage is ultimately expressed in district cooling and heating systems where individual users are decoupled through the means of gasketed plate heat exchangers (GPX). When GPX are used, cross contamination of HVAC fluids may also be prevented.The operator of the distribution system is isolated from the users and is not subjected to potential excessive static pressure.

Design considerations. The addition of tertiary pumps may increase the initial-connected horsepower of the system, but the level of control is increased. Under the right conditions, overall operating cost can be reduced. To optimize the performance of a tertiary-pumped system, control of the tertiary bridge modulating valve is critical. Tertiary bridge design. The same design criteria used for the secondary bridge should be followed (Fig. 4). Temperature sensor locations. Proper valve control requires that temperature sensors are located at the supply water temperature to the tertiary zone, T1; return temperature to the chiller plant, T2 (a low-flow bypass is maintained across the return control valve to provide an accurate water temper-ature); and the supply water temper-ature from the chiller plant, T3. Proper control permits the zone to operate at the highest possible temperature without control in the zone. This maximizes the flow through each coil and control valve providing better heat transfer and valve authority. Maximizing the flow in the tertiary also reduces the amount of water from the secondary. This reduces the flow in the secondary and may result in the reduction of the number of chillers on-line in the chiller plant.

. 4. Tertiary zone bridge Secondary pumps Secondary pumps are selected for present flow to minimize initial horsepower. The pressure drop across the control valve of the highest head zone must be included. Consideration should be

given for future flow conditions. Careful selection will permit the use of present flow pumps under future conditions. Since the secondary pumps are typically the largest pumps in the system, adjustable frequency drives and controls should be considered if economically justifiable. Tertiary pumps Tertiary pumps are selected based on the flow and head require-ments for the zone or building load. These pumps are often low horsepower and do not need to be of variable speed unless it is economically justifiable. If variable speed is elected, differential pressure sensors are located across the largest, farthest load and two-way control valve. Consideration must also be given to low flow conditions. These are similar to the design parameters for primary-secondary pumping systems. Zones close to the chiller plant may operate under high distribution piping differential head. If the differential head is sufficient at all times, tertiary pumps may not be required for the nearby zones. Primary variable speed pumping systems This type of system is not a variation of primary-secondary pumping. The concept behind primary variable speed pumping is the elimination of the secondary pumps to reduce first cost, space requirements, and maintenance (Fig.5). Constant volume is no longer maintained through the chillers. Variable system flow is directly achieved through the modulation of flow through the chillers. Primary variable speed pumping systems are especially attractive in primary-pumped retrofit situations since space may not be available for additional pumps and piping.

5. Primary variable speed pumping. Design considerations- Control logic and sequencing for the pumps and chillers is the heart of this type of system. With the advent of more sophisticated microprocessor controls, the potential problems associated with under-flowing or overflowing the chillers can be addressed. Operation of the variable speed pumps is also provided through the microprocessor control. Chillers Multiple chillers are required to maximize the turndown capacity of the chilled water plant. With only one chiller, the low-flow range is limited to the minimum flow of the single chiller. Multiple chillers lower the minimum flow limitation. The designer must know the minimum flow requirements for each chiller. Chillers of the same size, efficiency, and manufacture simplify the control sequence. Close coordination with the chiller manufacturer is highly recommended, especially in retrofit appli-cations.

Common pipe The common pipe is not eliminated in primary variable speed pumping. It is modified into a lowflow bypass. To ensure that minimum flow is always maintained through the chiller, a bypass with a modulating control valve is employed. As loads diminish, system flow reduces. When the system flow approaches the minimum flow requirement of the chiller, the modulating two-way valve in the bypass opens. The sum of the flow in the system plus the flow in the bypass must exceed the minimum flow requirement of the chillers. Flowmeters are installed in both the supply and the bypass to calculate the flow sequence. Primary pumps Primary variable speed pumps are selected in a manner similar to secondary pumps in primarysecondary pumping systems. Pumps should be of equal size and designed for parallel operation. Pumps with differing flow and head characteristics do not work well together in parallel. Careful selection will permit the use of present flow pumps under future conditions. Differential pressure sensor locations The principle method of pump control is differential pressure transmitters. As with other variable speed systems, the largest, farthest loads are usually the most critical to monitor. Sensors close to the chiller plant provide valuable information for minimizing system differential pressure during low flow conditions.

Table 1. Advantages and disadvantages of various pumping systems.

Conclusion There are many ways modern HVAC systems can be pumped. Each method has its own advantages and disadvantages to the user or operator (Table 1). The designer must consider present system use, plans for the future, cost considerations, and the ability level of the operator. With more tools in the toolbox, the engineer is better equipped to make the decision, Which system is the best for my client?

This article is an abridged version of a Fluid Handling Staff article that was originally published in the October, 1998 issue of HPAC magazine. Part I appeared in the January, 1999 issue of TechTalk 4. Reprinted from TechTalk June 1999, Volume 14, Issue 2

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