Ashrae 90.1 and the future of pumping part 1

Editor's Notes

• #14: A flo-trex valve is a multi function valve that replaces an isolating valve, a non-return valve and also an elbow. The valve can also be used to throttle the pump to aid the system commissioning process. The valve has a 45 degree split and can be rotated to change an angled valve to a straight configuration or visa versa. So, now we have reviewed our installation options, lets take a look at a savings example…………….
• #15: LEFT: BAYFRONT TOWERS, Tampa, FL Compact mechanical room with no space for two individual pumps and no space to mount drives on the wall. Simple single large AHU avoided using DP sensor by using sensorless design. Pumps also have auto alternating feature. Worked out of the box with only a slight adjustment to the minimum maintained pressure to accommodate the twin chillers minimum flow requirement. What is not shown in this picture is the two chillers and twin buffer capacity tanks and expansion control tank. There’s a lot of equipment in this little room! 4302 8x8x10-20 hp DualArm DE-IVS Sensorless unit we sold this past year. The DualArm IVS Sensorless pump has been in operation for almost ¾’s of a year. We took out an old water source Air Handler replacing it with a chilled water AHU, Twin Chillers, the IVS dual Arm, a buffer capacity tank, air purger and expansion tank all in the same room we took the old AHU out of…No small task. It worked right out of the box with only a slight adjustment to the minimum maintained pressure. The original set point was below the chillers minimum flow requirement. Otherwise – Flawless! RIGHT: SHOREWOOD PACKAGING, Danville, VA If no floor space, mount the pumps off the ground!! Commercial real estate cost $120/ sq ft, +50% Joe’s numbers on wall mounting?
• #30: Armstrong Vertical inline pumps with Design Envelope IVS integrated controls. Series 4300 pumps are available up to 350 hp with integrated controls. Series 4380 close-coupled pumps are available up to 7.5 hp with integrated controls.
• #33: Impeller trims are optimized to the motor power at the pump BEP. What exactly does that mean? It means we look for the intersection of the motor bhp line with the pump BEP and set our impeller trim to that motor. In this example, a 6x6x11.5 pump 40 hp uses an 11.50” impeller 30 hp uses a 11.44” impeller 25 hp uses a 10.78” impeller And a 20 hp uses a 10.00” impeller Any operating point in between the pre-set impeller trims is achieved by varying the speed. Why don’t we use the largest impeller?... This is the most efficient trim… This is true hydraulically. But through testing and experience, we found that the common asynchronous motor torque is not constant and at lower frequencies typically around 48Hz, the mechanical losses start to have an effect. Thus we have distinct impeller trims for each motor. Harmonics => 25/30 = 16.6% (no dollar cost per Danfoss) Total harmonic distortion reduction. *NOTE if anyone asks: impeller trims are based on water. For other fluids, the trim diameter is different.
• #38: This page looks at the starting currents for an AC motor. Remember that the more abrupt and higher the current start, the greater the wire sizing, to handle the current, the greater the possibility of demand charges and the greater the threat of water hammer, and broken pipes. Direct-On-Line: or “across the line” is the oldest way to start a pump. The power required to start the pump can go as high as 700% as shown above. As the pump approaches 60Hz the current drops. Start/Delta : One method to control the current is to shift between the motor coil configurations. The Star configuration is used to start the motor. When the motor reaches close to maximum speed, say 45Hz, a relay switches the configuration from a Star to Delta. Soft-Starters : These devices can be either electric timers which monitor and limit the voltage or they can be electronic which monitors and limits the current. Since these devices only control the voltage or the current, many of them can not be used for long periods of time, and usually can not exceed 30 seconds. VFDs : Control both the frequency and the voltage simultaneously. This gives full control over the acceleration and deceleration ramps. This is the best method of starting or stopping a pump but it is also, in most applications, the most expensive.
• #39: Peak amp draw = 35.1 FLA x start-up % kW = Peak amp draw x 460V / 1000 Demand charge = $/kW
• #47: A long list of savings that adds up to a LCC and a true value based offering.
• #49: In a 3 pump system shown here (NOTE: We don’t show the VFDs on the wall or integrated on the motor) But we eliminate the flex connectors, the concrete bases, inertia pads, no realignment of the flex coupling during commissioning. HSC versus VIL Assume 3 pump system - 6x5x12 versus 6x6x11.5 (2-duty / 1-standby) Installation cost = $19,572 vs $8,327 105.7 sf vs 44.2 sf; diff. = 61.5 sf and if we assume $150 / sf, that’s $9,225
• #50: LEFT: BAYFRONT TOWERS, Tampa, FL Compact mechanical room with no space for two individual pumps and no space to mount drives on the wall. Simple single large AHU avoided using DP sensor by using sensorless design. Pumps also have auto alternating feature. Worked out of the box with only a slight adjustment to the minimum maintained pressure to accommodate the twin chillers minimum flow requirement. What is not shown in this picture is the two chillers and twin buffer capacity tanks and expansion control tank. There’s a lot of equipment in this little room! 4302 8x8x10-20 hp DualArm DE-IVS Sensorless unit we sold this past year. The DualArm IVS Sensorless pump has been in operation for almost ¾’s of a year. We took out an old water source Air Handler replacing it with a chilled water AHU, Twin Chillers, the IVS dual Arm, a buffer capacity tank, air purger and expansion tank all in the same room we took the old AHU out of…No small task. It worked right out of the box with only a slight adjustment to the minimum maintained pressure. The original set point was below the chillers minimum flow requirement. Otherwise – Flawless! RIGHT: SHOREWOOD PACKAGING, Danville, VA If no floor space, mount the pumps off the ground!! Commercial real estate cost $120/ sq ft, +50% Joe’s numbers on wall mounting?
• #51: The VILs present a huge opportunity for pipe savings as they can be mounted directly to the chillers, boilers, and cooling towers. On average the pipe savings are reduced by 40-50%. Here’s an example of a plant room optimization for Glendale Arena, home of the Phoenix Coyotes. On the left are HSC. On the right the VILs are mounted directly onto the chillers saving 43% of piping. In this case, the pipe savings pretty well paid for the pumps. Ran AOL 2400 gpm @ 50 ft vs 2400 gpm @ 80 ft and looked at difference in op cost. 14477 vs 7893 = $6600.
• #52: The most common replaced item on pumps is the mechanical seal. Seal changeout is much faster 30mins versus 2 hrs compared to base-mount. Also 4300 VILs don’t use bearings which dramatically reduces failures and maintenance costs.
• #53: A long list of savings that adds up to a LCC and a true value based offering.