ACREX 2012

Optimization of Pumping System in HVAC

B. Srinivasa Rajkumar
Sales Manager (HVAC) Commercial Building Services Grundfos India

HVAC pumping schemes

All system operated as variable flow system Primary variable pumping Use of thermal storage Combination of active and passive systems Use of tertiary pumps (zone dividing) Challenges in condenser water pumping Remote monitoring of pumping systems

All system operated as variable flow system

Constant flow system:
Constant flow systems will use three way valves and will give a variable flow in distribution net and variable flow in the load.
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Constant flow Variable temperature

Variable flow Constant temperature

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Variable flow system:

Variable flow systems will use two way valves and give a variable flow in both the load and in the distribution net.
Variable flow Constant temperature

Constnt flow Variable temperature

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By using Tertiary pumps the flow in load can be held constant but with a variable temperature.

Variable flow Constant temperature

Constnt flow Variable temperature

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The way to - Primary variable flow

Constant flow Three way valves Constant speed pumps

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Improved performance

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Constant flow (primary) Variable flow (secondary) Two way valves Constant/variable speed pumps Constant flow (primary) Variable flow (secondary) Two way valves Constant/variable speed pumps Variable flow Two way valves Variable speed pumps

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Common pipe

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Buffer tank

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Primary variable flow

Also the using primary variable flow has been discussion in leading technical magazines like The ASHRAE Journal. The conclusion often end up in favour of: Primary variable flow

Primary variable flow

Advantages: Lower first cost Less space required (less pumps) Reduced pump power design Lower energy consumption
Between a flow at 50% to 80% we have the highest number of operation hours, and here the saving is significant.

Primary variable flow

Primary/tertiary dedicated pumps:
If there is a demand for standby pumps there has to be installed one standby per chiller. The pump controller has to be able take out the pump of control sequence when the chiller is switches off.
Chiller Chiller Chiller
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Primary/tertiary common pumps:

There is a demand for control valves on each chiller to be able to control the flow in the chiller, and there is only demand for one standby pump for all the chillers.
Chiller Chiller
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For both system types there is a demand for controlled bypass to secure the minimum flow.

Primary variable flow example 3 x 600 TON chillers

When the combination of primary pumping , dedicated pumps and proportional diff. pressure, it is very important to have the right control of the pumps and the chillers. This means switching chiller/pump 2 before chiller/pump 1 reach maximum capacity. 3 X 327 m3/h @ 45 m pumps
In this example maximum flow are: One Chiller/pump: 240 m3/h Two Chillers/pumps: 580 m3/h Three Chillers/pumps: 980 m3/h
Chiller 1 Chiller 1+2 Chiller 1+2+3

Use of thermal storage tanks

Reduced refrigeration equipment investment Less expensive than chiller capacity in large systems Less inefficient part-load operation of plant Capacity for emergencies and growth
Basis thermal storage tank principal
Stage storage tank

Chiller plant

Distribution net

Charge mode flow

Discharge mode flow

Use of thermal storage tanks

Use of thermal storage provide a good opportunities to cover the peak load instead of installing more capacity, also in situation where the system is expanded.
Load Capacity handle by chillers and storage Capacity handle by chillers 24 hours

Combination of active and passive systems

To reduce the size of the air part (ducts and AHUs) passive systems are often used it could be cooling ceilings or cooling floors. The passive system also has an advantage in operating with a higher flow temperature (15-17oC) which fit with alternative cooling sources and make it possible to operate with a higher system Dt. The big challenge is to avoid condensation on floors and ceilings.
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15oC

Cooling Ceiling/floors as a part of the building construction

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18oC
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Combination of active and passive systems

Typical buildings where passive system can be use are buildings with large public areas like: Air ports Hotel receptions Museums Opera houses etc. Passive systems always has to combined with chilled air system to provide fresh air.

Use of tertiary pumps

No matter if the system design is a Primary variable flow or Primary secondary flow tertiary can be used larger systems. The main purpose is to increase the hydraulic balancing and to lower the head of the Primary/Secondary pumps and there by reduce the operation cost. The system will be much more flexible easier to make changes.
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Chiller De-coupling

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Use of tertiary pumps

The tertiary system/pumps can be connected to the distribution net in different ways depending on the individual conditions.
Connection with booster pump and high pressure bypass

Direct connection

Connection with control valve

Connection with booster pump

Indirect connection with flow temperature control

Indirect connection with flow temperature control, and by-pass control

Indirect connection with flow temperature control, and and heat exchanger

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Use of tertiary pumps

When to use tertiary pumps: In large system capacity system

To be able to reduce the head of the primary pumps
Increase the hydraulic balance

Where there is a combination of active and passive systems

To be able to operate with different flow temperature

Where there is a combination of AHU and fan coils

Increase the control of the system

In tall towers (with heat exchangers)

Separation of the system to avoid high static pressure

Potential Challenges in Condensers Circuit

Condensers circuit are Primarily a much easier to manage. However, troubles still persist occasionally in some system. Lets have a brief look at some of the potential challenges: 1. Pump Cavitations due to insufficient inlet pressure 2. Air entering pumps due to the formation of vortex at collection basin or incorrect setting of bypass 3. Over sizing of pump due to over estimation of frictional losses in the circuit 4. Fouling of pipes and condenser tube 5. Changes in operating condition for circuit with bypass line

Closed Loop and Open Loop system

In a large chilled water system consists two difference kind of circuit

Closed loop system- Distribution circuit Closed systems are characterized as systems with pumps that only have to overcome the sum of friction losses, which are generated by all the components Open loop system- Heat rejection circuit Open systems are systems, where the pump is used to transport liquid from one point to another Thing to note between these two type of circuit while sizing the pump is Static head consideration.

System Curve for Closed/ Open Loop system

Closed Loop system

Open Loop system

Typical Heat Rejection Circuit

Cooling Tower

Chiller

Condenser Pump

Condenser side is an open loop system, the only positive pressure to the pump suction are the elevation of cooling tower and atmospheric pressure, therefore, here are a few notes; Always locate the condenser pumps as close as possible to the tower Design the pumps below As much as possible below the collection basin water level Locate the condenser pumps before Condenser to avoid large pressure drop of this component Ensure sufficient NPSHA. Avoid using high pressure drop strainer, check Valve and balancing Valve at pump suction line (If strainer has to be installed, try to use large mesh opening up to 3/16 at the suction, propose is just to protect the pump and install a fine mesh strainer at the pump discharge to protect all other equipments) Avoid Overhead suction piping

Points to note to avoid cavitations on Condenser pump

Vortex at Collection basin Exit

Vortex at Collection basin is created when, there is insufficient water level above the collection basin exit for the velocity that the water is exiting. Facts contributing to the vortexing:1. Sudden decrease in exit pipe size (Suction line) causes the water velocities above the maximum allowable limit, vortex created 2. Over sizing of pumps due to over estimation of frictional losses 3. In correct setting of bypass line (If any)

Points to note to avoid formation of Vortex

Cooling Tower exit pipe follows collection basin exit at least for the length of 10x the diameter before reducing it to the pump suction size Throttle valve to control flow (energy consideration) Modifying impeller diameter Speed control

Remote monitoring of pumping systems

Why to own when you can rent the services ? World is moving towards cloud computing. So does the building services No hassles of maintaining a local network All devices talk to each other and to a central network Nominal charges for web service maintenance to the use

Remote monitoring of pumping systems

Easy-to-install, low-cost monitoring and management of pumping systems.
Alarms on SMS and Email distributed according to built-in week schedule. Web access to reports and trend data for all relevant employees.

Automatic event log and service log for all pumps in the system.
Plug n Play integration with Controls monitoring of all pumps and sensors. Centrally hosted database and application server. Users only need an Internet PC.

Cloud Overview
Users

Internet

GSM
Pump Logic Controllers Data logger

Central Web Server

Users

Remote monitoring of pumping systems User benefits

Online monitoring of pumping system efficiency Close monitoring of specific energy consumption Immediate course correction in event of any performance degradation Get access to data and perform basic functions such as acknowledge alarms, start/stop pumps, reset controllers from your mobile phone / PDA Business model could cover AMC or 24/7 operation support to benefit users

Focus on energy saving (Carbon footprint)

Energy saving: To reduce operation cost To reduce CO2 emission Utilizing energy sources better

The use of Life Cycle Cost more and more common

How to evaluate the most efficient pump solution

The best way to evaluate the efficiency of a pump system is to use: Life Cycle Cost Analysis (LCC) LCC shows the total life time cost of a pump system. The lifetime of a quality pump system will be no less than 20 years. When used as a comparison tool between possible design or overhaul alternatives, the LCC process will show the most costeffective solution within the limits of available data.

The LCC equation

Normally only 3 elements in the equation will add value when calculating HVAC systems in Commercial Buildings :

Initial cost Maintenance cost Energy cost

B. Srinivasa Rajkumar Manager Sales (HVAC) Commercial Building Services Grundfos Pumps India Direct: (+91) 44 4596 6891 Mobile: (+91) 99406 79196 Mail: srinivas@grundfos.com