Post on 11-Dec-2015
description
Singapore – June 2012 Singapore – June 2012
Agenda
1. Pump Configurations & Installations
2. Variable Speed Pump Basics
3. ASHRAE 90.1 requirements for
Variable Speed Pumping and
Balancing
4. All Variable Speed Chilled Water
Plant Control Methodology
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Pump types
Vertical Inline End Suction
Horizontal Split Case
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Vertical InLine - 14x14x15 150hp
Suction
Diffuser
Triple Duty
Valve
• Easy to install
Pipe mounted directly into
piping - Smallest footprint
is inherent
• Eliminate cost of
flex connections
and inertia bases
• Minimal
commissioning
costs
• Self contained unit
• No site grouting costs
• No alignment costs or
concerns
• No lubrication
required or seal
adjustments
necessary
• No Pump Bearings
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4300 - 14x14x15 150hp
Pressure
Gauge
Sight Glass & Filter
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Vertical Inline – Grooved Systems
• 20x20x19 Pump
• Pipe Line Mounted & Supported
• Inertia Base Not Required
• Flex Connectors Not Required
• No Alignment Required
• 1 Mechanical Seal to Maintain
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Primary CHW Pumps
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Condenser Pumps
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8
GuangHui Project Taiwan 60 000 tons of refrigeration
46-16x16x15 300 hp
23 -3000 ton Chiller installation
Dedicated Pump For Chillers
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Dedicated Pump - Chillers
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10
Ford Plant in Mexico
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Dual Pumps – Typical Mounting
Seismic Installation
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Flotrex & Suction Guides
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Triple Duty Valve
•Drip-tight Shut Off Valve
The Armstrong Flo-Trex valve is designed
and tested for drip-tight isolation at
150% of maximum working pressure.
•Flow Throttling Valve
The Armstrong Flo-Trex valve uses a plug and disc
design which is the most effective valve type for
combining throttling of flow and isolation. Other
design valves may be effective for throttling or
isolation, but not both
•Non-slam Check Valve
The Armstrong Flo-Trex valve incorporates a spring
closure design that closes the valve in a controlled
manner, protecting the valve from slamming due to
a reversal in flow caused by gravity or recirculation
from a parallel pump.
•Convertible Body Design
The Armstrong Flo-Trex convertible body design
permits the valve to be changed on-site from
straight to angle configuration
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Suction Guide
•90˚Elbow
Mounting the Suction Guide on any pump
Suction turns the piping 90°, replacing an
elbow. In addition, the Suction Guide can be
rotated to any position allowed by the pump
suction bolts, from vertical to horizontal.
•Inline Strainer
The stainless steel strainer has free area of at least
250% of pipe sectional area. A disposable finemesh
strainer is installed for start-up.
•Reducing Elbow
The Suction Guide connects same size piping to
the pump suction, but can also connect to inlet
piping one size larger than the pump suction,
eliminating a reducing elbow.
•Guide Vanes
Flow stabilizing vanes on the outlet allow the Suction
Guide to bolt directly to the pump, saving the space
and cost of a long straight pipe
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Vertical Inline – Mechanical Seal Removal
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End SuctionBase Mounted
Pump
A comprehensive range of single stage,
end suction, radially-split centrifugal
pumps designed for a wide variety of
applications. Features self-venting
casing to prevent air binding, heavy duty
bearings that are sealed and lubricated
for life, back pull-out bearing frame for
easy removal, and self-lubricating
mechanical seal to prevent liquid
seepage. Available in bronze fitted, all
bronze and all iron construction.
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4030 Base Mounted Pump – Cross Sectional View
Single spring mechanical seal with O-ring
mounted silicone carbide seat provides
leak-proof operation throughout pump range.
Bearing assembly
two anti-friction bearings,
permanently lubricated,
carry design loads with
minimum.
A heavy fabricated steel baseplate, rigidly constructed to ANSI/HI 1.3.5
standards, provides for proper alignment of pump and motor.
Base supported casing
eliminates need to support
casing when bearing
assembly is removed
Stainless steel
Shaft Sleeve
Dynamically
balanced
cast bronze or
iron impeller
Radially split casing provides pull out design
that allows removal of bearing assembly and
impeller without disturbing pipe connections.
Drilled and tapped connections
for gauges and drain.
ANSI flanges.
Top centerline discharge
ANSI style casing, self
venting to eliminate
pump vapor lock
Gasket, non-asbestos,
confined as
recommended by ANSI.
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Base Mounted Pumps – Base, Grouting & Alignment
Grouting
Alignment
Base
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Base Mounted Pumps – Flex Connectors
Flexible Connectors
Straight Section
5 to 10 Pipe Dia.
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Hillcrest Recreation Center
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Base Mounted Pumps – Concrete Base & Spring Isolators
Spring Isolators
Form for Concrete
Base
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COMMERCIAL PUMPS Model 4600 HSC
The Series 4600 is the state of the art
Horizontal Split Case pump – based on the
"Tilted Parting" concept to minimize
turbulence at the eye of the impeller by its
straight laminar approach, thus
maximizing efficiency. This also results in
the lowest profile and minimum floor
space of any HSC pump, lowering
installation costs. Cartridge seals and
bearing removal nuts ensure ease of
maintenance.
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COMMERCIAL PUMPS Model 4600 HSC
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Double Suction Pumps
require approx. 30%
more space
Inertia Bases
Alignment
Grouting of bases
Vertical In Lines cost
less
COMMERCIAL PUMPS Model 4600 HSC
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Typical HSC Installation
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Variable Speed Pumping
Presented By Rocco Logozzo – S.A.Armstrong Limited
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Vertical inline pump
How a pump works
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Centrifugal Pump Characteristics
Flow
Efficiency
Power
Head Design Duty
BHP = GPM x Head (ft) ______________
3960 x Pump Eff. %
KW = BHP x .746
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For conditions of 1000 USGPM at 100 Ft a 4300 6x6x11.5 may be
used with a 40 HP motor – 11.36” impeller diameter
Note that this is maximum non-overloading
impeller diameter for 40 HPmotor
Pump Basics – Pump Selection
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Why Variable Speed Pumping?
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HP
Speed/Flow
Energy used
at rated speed.
Nominal
Power
Nominal
flow
The power consumed = Speed ³
The Cube Law
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22 Kw pump at 50% of rated speed
Power = 22 Kw x (0.5 x 0.5 x 0.5)
Power = 2.75 Kw (12.25% nominal) Energy Used
50% flow
12.75%
50%
Kw.
Speed/Flow
Nominal
Power
Nominal
flow
The power consumed = Speed ³
The Cube Law
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Fixed Speed Pumping
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Typical Secondary Pumping Loop (Constant Flow)
Fixed Speed Pumping
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DESIGN CONDITIONS: 1000 GPM @ 100 Feet 63 L/s @ 30.5 Meters
Fixed Speed Pumping
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Constant Flow System to Variable Flow System
Fixed Speed Pumping
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OPERATION POINT: 500 GPM @ 122 Feet 31.54 L/s @ 37 Meters
Power Savings: Flow @ 50% (Constant Speed Pump)
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Power Savings: Flow @ 50% (Constant Speed Pump)
Usgpm Ft. HdPump
RPMPower HP Efficiency
1000 100 1760 31.3 80.7
500 122 1760 22.5 68.9
Power Savings: 28%
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Variable Speed Pumping
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Typical Strategy 1 – Constant head at
pump for Secondary Pumping Loop
Variable Speed Pumping
Basic Requirements
1. Pumps
2. VFD’s
3. DPS (Differential Pressure Sensor)
4. DPS Set Point *
*Depends where it’s located in the
the system
If its close to the pump’s supply &
Return, the set point would be same as
the pump’s differential pressure.
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OPERATING POINT: 500 GPM@ 100 Ft
Flow @ 50% DP Sensor across pump (100 Ft)
DP Set Point = 100 ft (298 KPA
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Additional Savings over riding pump curve: 22%
Power Savings: Flow @ 50% DP Sensor across pump
Usgpm Ft. HdPump
RPMPower HP Efficiency
1000 100 1760 31.3 80.7
500 100 1599 17.5 72.0
Power Savings: 44%
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Typical Strategy 2 – Constant Head at Index
Point for Secondary Pumping Loop
Variable Speed Pumping
What is the DP set point
if the sensor is located further
away from the pumps?
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OPERATING POINT: 500 GPM @ 63 ft 31.54 L/s @ 188 KPa
Flow @ 50% DP Sensor across coil & CV
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Additional Savings over maintaining plant DP: 42%
Power Savings: Flow @ 50%
DP Sensor across coil & CV
Variable Speed Pumping
Usgpm Ft. HdPump
RPMPower HP Efficiency
1000 100 1760 31.3 80.7
500 63 1288 10.2 78.2
Power Savings: 67%
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Typical Strategy 3 – DP Sensor across the Control Valve
DP Sensor located at the farthest point
sometimes called the Index leg
Problems could result where coils are
under flowed during part Load
How do we solve or mitigate this
Problem?
1) Multiple sensors
2) Manual Balancing with DP Controller
3) PICV Valves
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Flow @ 50% DP Sensor across CV
OPERATING POINT: 500 GPM @ 48 FT
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Power Savings: Flow @ 50% DP Sensor across CV (30 ft)
Usgpm Ft. HdPump
RPMPower HP Efficiency
1000 100 1760 31.3 80.7
500 48 1141 7.5 80.4
Power Savings: 76%
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Power Savings - Summary
Variable Speed Pumping
System
Type
Pump
Speed
Sensor
LocationUsgpm Ft. Hd
Pump
RPMPower HP Efficiency
Power
Savings
Constant Constant None 1000 100 1760 31.3 80.7 0%
Variable Constant None 500 122 1760 22.5 68.7 28%
Variable Variable Pump 500 100 1599 17.5 72.0 44%
Variable Variable Load&CV 500 63 1288 10.2 78.2 67%
Variable Variable Valve 500 48 1141 7.5 80.4 76%
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6.7.2.3 System Balancing
• “All HVAC systems shall be balanced”
• “Written balancing report for conditioned areas exceeding 5,000ft2
(500m2)”
• “Hydronic Systems shall be Proportionately Balanced in a manner to
first minimize throttling losses”
6.7.2.3.3 Hydronic System Balancing
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Unbalanced System
• OA = 100°F
• A needlessly large volume
is pumped. This increases
the energy consumption at
both the pump and chiller
• The return water
temperature is quite low.
This reduces the efficiency.
It also reduces the capacity
of the chiller to 79%
• A 250 Ton chiller is used,
but it supplies only 197.5
Ton (79%).
# 1
# 2
# 3
# 4
# 5
# 6
* 790 GPM
** 51°F
*** 250 TON CHILLER
197.5 CONTROLLER
T = 6°F 45°F
15
25
50
100
200
400
65
63
64
59
61
55
58
51
54
48.5
51
93°F / 30% BTU
89°F / 45% BTU
83°F / 70% BTU
75°F / 100% BTU
70°F / 120% BTU
65°F / 140% BTU
F
F
F
F
F
F
GPM
T = 3.5°F
T = 6°F
T = 10°F
T = 14°F
T = 18°F
T = 20°F
CHILLER
79%
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Balanced System
• OA = 100°F
• The correct volume is
pumped and no more
pump energy than
necessary is used
• The “design” return water
temperature is
accomplished. Efficiency is
improved. 100% capacity
can be provided.
• The capacity of the chiller
is utilized to 100%.
# 1
# 2
# 3
# 4
# 5
# 6
* 600 GPM
** 55°F
*** 250 TON CHILLER
(250) CONTROLLER
T = 10°F
100
100
100
100
100
100
75°F / 100% BTU
75°F / 100% BTU
75°F / 100% BTU
75°F / 100% BTU
75°F / 100% BTU
75°F / 100% BTU
°F
°F
°F
°F
°F
°F
GPM 55
55
55
55
55
55 T = 10°F
T = 10°F
T = 10°F
T = 10°F
T = 10°F
T = 10°F
45°F
CHILLER
100%
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Typical Strategy 3 – DP Sensor across the Control Valve
DP Sensor located at the farthest point
sometimes called the Index leg
Problems could result where coils are
under flowed during part Load
How do we solve or mitigate this
problem.
1) Multiple sensors or move sensor closer
2) Manual Balancing with DP Controller
3) PICV Valves
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Differential Pressure Controller
Protect Control Valves from large differential pressure variations
experienced at varying load on the system
Good Control Valve Authority is maintained at part load
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PICV Standard EQM control valve
PICV – Pressure Independent Control Valve
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DE –IVS: Sensorless Pump Control & Design Envelope
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Design Envelop HVAC Pumping
Pumping unit complete with motor integrated VFD
and controls
•Simply wire power as any pumping unit
• Motors will not overload – Controls allow max
motor nameplate current only
• Supplied with 208V, 230V, 380V, 460V or
575V, ODP or TEFC motors
• Available with Sensorless control
• Sensorless feature can be disabled &
controlled through an Pump Controller, or BAS
via all common communication protocols
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Evolving
Brand1 Brand 2 Brand 3 Brand 4 Brand 5
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Sensorless Pump & Motor Data
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Sensorless Control
• Pump & VFD units are supplied with Sensorless
Control as standard, where available
• Sensorless Control may be switched at the factory [or
on-site] to another control strategy (BMS, Pump
Controller & remote sensor, etc)
• Keys to Sensorless Control are:
• Knowing where the pump is operating
• Knowing where the pump should be operating
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Sensorless Control
• Knowing where the pump is operating
• How do we do that?
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Pump curve derived from pump test
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Flow / head requirements predict power & efficiency at rated speed
7500gpm at 45 m design
242.08hp at 86.83% efficiency
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Flow / head predicted from power & speed
240.35bhp at 58.8Hz
indicates unit operating at 7500gpm at 45 m head
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Design Envelope & Sensorless Control
• Knowing where the pump should be operating
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Design Envelope IVS – Where it should operate …
A
B
Head
Flow
Min
. H
ead
System
Design Speed
A
B
Design Point
Minimum Head
Pumps
Cooling coil
Minimum Head equates to sensor setting at remote cooling coil in traditional system
Operating curve for
temperature control
with DP sensor
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He
ad
Flow
Po
we
r
1
2
S1 S2
IVS Sensorless Pump Technology
Original System
Curve
Control Curve
S1 System Curve
S2 System Curve
P1
P2
Operating point is wherever pump
performance curve intersects
system resistance curve
Traditional Sensorless Control
Operating point is where pump
performance, system resistance and
control curves converge
Design Envelope – Sensorless Control
1 – Satisfied Flow & Head
Operating Point (S1 System
Curve)
P1 – Power at current flow &
head
S1 – Operating Speed pump
curve
2 – Satisfied Flow & Head
Operating Point (S2 System
Curve)
S2 – Operating Speed pump
curve
P2 – Power at current flow &
head
How do we get from 1 to 2?
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Sensorless reduces speed and
chases equilibrium down control
curve until correct power & speed
ratio stabilizes at the new S2
system curve at 2 (S2 speed curve)
Operating point begins to move to
the left from 1 on S1 speed curve;
power reduces as it does so;
incorrect speed for the new power
value is recognized immediately;
System has CV modulating closed
resulting in a steeper S2 system
curve
Speed is stable at 1 until system
control valves (CV) modulate.
IVS Sensorless Pump Technology
Original System
Curve
Design Envelope – Sensorless Control
1
2
S1
S2
S1 System Curve
S2 System Curve
How do we get from 1 to 2?
Reverses as CVs open
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Design
Point
As-Built
System
Motor
Power Line
Flow
Head
Pump Performance
Curve – Full Speed
PUMP
OPERATING
CURVE
Pump Performance
Curve – Design Speed
Minimum
System Pressure
(Typical Sensor
Setting)
System Curves –
Varies with load valves
Variable Speed Paradigm Shift Operating Point
As-built system:
System losses lower than
design – Motor cannot
overload. Operates at speeds
at or below motor current limit
Part load system needs –
Higher Efficiency than
constant speed. Lower
system pressure allows load
valves to operate in design
diff pressure range
Capability Envelope
Part
Load
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Optimized capacity and motor power
• Impeller trim is optimized to the motor power
• Electronic load limiting
53.5 lps @ 27 m
18.5 kW vs. 22 kW traditional Savings in smaller
motor & controls
Motor/integrated
controls = € 350 or 9%
Power wiring = € 40
Harmonics = 16.6% reduction
A B Pump with Integrated VFD
(18.5 kW)
A C Traditional pump (22 kW)
A
C
BEP
B 15 kW
18.5 kW
22 kW
30 kW
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Design Envelope advantages
Envelope selection reduces risk and cost
A
B
C A – Original design
B – 2nd
design
C – Final design
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Energy Metering Capability
• Use the Integrated Controls as an energy meter for energy
measurement verification
kWh
readout
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Flow Display
• Flow meter savings
• Ability for digital flow readout and communication to
BMS
• More capabilities coming in future
=
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Wall Space Savings
No room
on wall
for multiple
VFDs
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Reflected Wave Voltage
• If distance between the motor and the control is long, a
standing wave can form between the motor and control
• These waves can increase voltage at the motor terminals
causing the motor insulation and bearings to fail prematurely
• Locating the control with the motor will minimize this
problem
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Harmonics - What is it?
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Harmonic distortion
Fundamental
Summation of all
harmonic frequencies
Voltage distortion
may cause sensitive
loads to
malfunction
Current distortion
causes heat in the
transformer and its
power lines
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Harmonic Causes
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Harmonic Solutions
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Harmonic Solutions
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Harmonic distortion
• IEEE 519-1992 is a standard for limiting harmonics
• Measured at Point of Common Coupling (PCC)
• Stricter limits at higher voltage
• Prevent one customer from harming another
• Not intended to be applied within a user’s system
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Harmonic Distortion
DC Link Reactors
built into IVS controls
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Harmonic Distortion
• Variable Speed Drives with built-
in DC line reactors (equivalent to
5% AC line reactors)
• Other drives often need external
AC reactors (for 30 HP estimated
cost is $440): Mitsubishi, Hitachi,
Lenze/AC Tech, Yaskawa*,
Schneider, Eaton*, Siemens
* Some models only
External AC line reactors
5HP
125HP
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Emission and immunity requirements
• Design Envelope IVS pumps include RFI filters to
ensure compliance to low emission and
immunity requirements EN61800-3 to the 1st
environment class CI (EN55011 unrestricted
sales class B).
• Wall-mounted drives often do not include these
and must be provided as an extra.
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CHW Retrofit Installation
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MLCC Project – Boiler Retrofit
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King’s Yard Energy Centre / Olympic Park
London, UK
King’s Yard Energy Center
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(HES with VFD vs. VIL with VFD
Wiring required between VFD
& Disconnect Switch & Motor
Mounting Bracket for VFD or
labor
Sensors or Installation
Required
Pump Inertia Base & Grouting
Installation
Alignment
Flex Connectors
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“All-Variable” speed CHW plants
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Primary – Secondary Pumping
C
H
I
L
L
E
R
C
H
I
L
L
E
RR eturn
Supply
Prim ary-
Secondary
C om m on
C
H
I
L
L
E
R
Load System
Source System
Prim ary Pum ps
D istribution System
Secondary Pum ps
Expansion System
• Common Pipe: Sizing is very Important
• Primary Pumps should not interact with
Secondary Pumps.
• Primary & Secondary side must
both be balanced
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Variable – Primary Plant Layout
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CHW Plant Basic Design
•Systems have operated for
decades in these modes.
•Traditionally equipment has
been sized for the best
efficiency at full load, or
design day conditions.
•Lets consider in detail the
operation of each of the
active components to better
understand how we could
save energy.
C ondenser
W ater Loop
C ooling Tow er
B uild ing Load
C hilled W ater LoopC hiller
C hilled W ater Pum p
C ondenser
W ater Pum p
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CHW Plant Basic Design
C ondenser
W ater Loop
C ooling Tow er
B uild ing Load
C hilled W ater LoopC hiller
C hilled W ater Pum p
C ondenser
W ater Pum p
PID LOOP
PID LOOP
PID LOOP
Three PID Loops, behaving independently.
Capacity based sequencing.
Complex “reset” for strategies for light load.
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Typical Chiller Design
Chiller (Refrigerant Loop)
Traditional constant speed
chillers have a fixed
speed compressor. The
expansion control valve
adjusts to modulate the
amount of refrigeration
work to achieve a
setpoint chilled water
supply temperature.
Typical Centrifugal Chiller Schem atic
C om pressor
Q (out to tower) 54F
44F
Q (in from load C H W )
Expansion Valve
Evaporator (Low T ,
Low P)
C ondenser
(h igh T , H i P )
Compressor bearings require
lubricant = oil management
systems
Heat energy moves naturally from a warm to cooler medium. To move heat
energy from a cooler medium to a warmer medium requires external “work”,
these devices are referred to as refrigeration devices, in our industry we know
them as Chillers.
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“All-Variable” speed CHW plants
•Decrease Condenser Temperature – Condenser Relief
•Increase Chilled Water Supply – CHW Reset
•Stage Chillers, Pumps, Towers & Tower Fans
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Variable Speed Devices are More Efficient at
Part Load by Design Intent
Variable speed Constant speed
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"Natural Curve"
of VS Centrifugal Chiller
To achieve optimum
performance, chillers
should be
sequenced such that
the on-line chillers
operate as close as
possible to their
Natural Curve.
"Natural Curve" of a
Chiller
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Cooling Tower Basics
Cooling Tower
• Rejects heat to atmosphere
through evaporative cooling
• Water air exposure maximized
by panels and fans
• Water molecules passing
through phase change to
vapor phase take heat energy
– molecules remaining in
liquid phase give up heat
energy to phase change =
cooling of liquid
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Tower ETW Approach Temperature For 3 Tower Systems
The total power to fans
and pumps is the
same for the variable
speed and constant
speed systems at each
condition. Note the
improved approach by
slowing, not shedding
towers at low loads.
Natural Curve
Effect with Variable Flow and Fan Speed Tower
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Optimizing All-Variable Speed Configurations:
The "Equal Marginal Performance Principle"
Trade off equipment loading in one device to pick up more load on
another, and achieve the same net “kW cooling” for lower kW electrical
input.
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Equal Marginal Performance Principal
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Demand Based Control
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Plant KW/Ton measured in real time
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Chiller and Tower recommendations
• The lower the turn down capability of each device, the
greater the efficiency of the plant.
• The variable speed chiller should have 70% load
turndown and includes serial communication (Lonworks,
BACnet, Modbus, or P Lan .
• The cooling towers must be selected for a 40% or greater
flow turndown
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