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
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L
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E
R
C
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E
R
C
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E
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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
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L
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E
R
C
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C
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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
