armstrong fluid technology | ashrae qatar oryx … · achieving ashrae 90.1 and 189.1 with...

Achieving ASHRAE 90.1 and 189.1 with Armstrong Design Envelope Green Building Solutions - ASHRAE Seminar 2014|May 03, 2014

Armstrong Fluid Technology | ASHRAE QATAR ORYX CHAPTER - Seminar 2014

Achieving ASHRAE 90.1 and 189.1 with Armstrong Design Envelope Green Building Solutions


Heat Transfer Fluid Flow Variable Speed Demand Based Control

Integrated Solutions

Pumping Units Integrated Fluid Management

Re-Commissioning and Service

Integrated Plant Packages

Optimum Life-Cycle Building Performance

Armstrong Core Competencies……


Agenda

•Peter Wolff: Exceeding ASHRAE 90.1 Best-practices in Pump ApplicationsDemand-based Pump Controls

•Rajmohan Govindraj:Exceeding ASHRAE 189.1 Demand-based Plant Controls


London Heathrow

Los Angeles

Qatar

Toronto Canada

Berlin Germany10%-60% of design load 90% of the time

Worldwide

Design Envelope selection methodHVAC is a global part-load industry

Presenter

Presentation Notes

The HVAC industry recognises that although global temperatures may be rising, the demand for heating and cooling are a fraction of peak load for most parts of the year. The data on the graph shows that whether the climate be temperate in Europe, continental in Toronto, Mediterranean in Los Angeles or sub tropical in Cairo, demand rarely hits peak load. The challenge for the industry has been to design, develop and operate systems that adjust their outputs to part load situations without losing efficiency. This presentation will show how Design Envelope can deliver this promise.


ASHRAE Standard 90.1 - 2010

•ASHRAE 90.1 is an energy standard for buildings

•It provides the minimum requirements for the energy-efficient design of buildings

•Most North American building codes have adopted ASHRAE 90.1 standards

•The 2010 version is expected to be adopted by North American building codes on October 18, 2013

Presenter

Presentation Notes

Most North American building codes are currently using the 2007 version of the 90.1 standard. The latest 90.1 standard is the 2010 version. A 2013 version should be released fairly soon and it is expected to have more stringent minimum energy requirements.


ASHRAE 90.1- 20106.5.4 Hydronic system design and control

• “6.5.4.1 Hydronic variable flow systems• Individual chilled water pumps serving variable

flow systems having motors exceeding 5hp(3.7kW) shall have controls and / or devices(Such as variable speed control) that will result inpump motor demand of no more than 30% ofdesign wattage at 50% of design water flow”

• Note that the ASHRAE 90.1-2010 requirement starts at 5hp (3.7kW) motors.

• Compare this to the 2007 version which started at 50hp (37kW)

• Progress to all pumps 1hp (0.75kW) and over having integrated controls

Presenter

Presentation Notes

Section 6.5.4 of the ASHRAE 90.1 standard states… Armstrong recommends that all pumps 1hp and above should have integrated controls. (Consider the fact that the industry has introduced half watt variable speed circulators).


Building load profile

Traditional pumpsare designed for best efficiencyoperation here.

Pumps should bedesigned forBESTEFFICIENCYoperation here.

Presenter

Presentation Notes

Looking at a building load profile, the ASHRAE 90.1 standard makes a lot of sense. Most systems operate at less than 60% capacity 90% of the time or more. Traditionally, pumps have been designed for peak demand but they should be designed for best efficiency operation where it spends the majority of its time- at 50% of the load. This results in lower energy consumption, reduced operation costs and improved equipment reliability. (Using a car analogy, it’s like designing a car for best fuel efficiency at 140mph! You rarely drive that fast so it makes more sense to design it for best efficiency where you operate most often. This is what provides the best value to an owner).


“Hydronic systems shall be proportionately balanced in a manner to first minimize throttling losses; then the pump impeller shall be trimmed or speed adjusted to meet design flow conditions”

ASHRAE 90.1- 20106.7.2.3.3 System balancing

Presenter

Presentation Notes

Written balancing report provided to owner for conditioned areas exceeding 5,000ft² (500m²)


Flow

Hea

d/P

ress

ure

Why have throttling ability in variable flow system?

Triple duty valves• Isolates

pump•Check feature•Throttle

AVAILABLE if system is outside pump operation• Reducing

speed will not achieve this

•Use on all pumps

•90° elbow when needed

System Resistance

Speed 1

Speed 2

A

D

A = Design PointB = Actual Site Duty Point C = Reduced Speed

without throttlingD = Reduced Speed with

Throttling

BC


ASHRAE 90.1- 20106.5.4.5 Pipe sizing

• “All chilled water and condenser water piping shall be designed such that the flow rate shall not exceed the values listed in table 6.5.4.5 for the appropriate total annual hours of operation.”

• Separated into 2 categories1. Variable flow/variable speed systems2. All other (constant flow) systems


ASHRAE 90.1- 2010Table 6.5.4.5 – Pipe sizing

Presenter

Presentation Notes

Note that the recommended pipe sizes are generally larger in the 90.1-2010 version over previous versions. This is to ensure pressure drops are reduced. However, the pipe sizes are now smaller for variable flow compared to "other" applications - this is consistent with pumping for part-load operation.


ASHRAE 90.1- 20106.5.4.5 Pipe sizing

Example: 1400 USgpm

• Another example of cost savings from variable speed, Design Envelope pumps:• 10" pipe x 100 ft long = $4,640 pipe cost• 12" pipe x 100 ft long = $5,260 pipe cost

• A $620 (or 12%) savings can be found with using smaller pipe -another reason that all pumps over 1 hp (.75 kW) should have integrated controls.

90.1 Standard Pipe2007 8”

2010 – Variable 10”

2010 – Constant 12”


HVAC pump requirements in ASHRAE 90.1

Energy savings through:

• Flow control• Balancing• Pipe sizing


3 Basic pump configurations

Horizontal split case

End suction

Vertical in-line


Horizontal split case

Inlet

Outlet

Coupling

Bedplate


Horizontal split case – vertically mounted

InletOutlet

Coupling

Bedplate


Horizontal Split Case - top suction and discharge

Inlet Outlet

Coupling

Bedplate


End suction pump

Inlet

Outlet

Coupling

Bedplate


Split coupled Vertical in-line

InletOutlet

Coupling

No Bedplate


Armstrong recommends this configuration be used up to 7.5 hp only (Design Envelope 5 hp only) due to weight and handling of motors during seal changes.

Vertical in-line


Which is the bestconfigurationfor the application?


A. Floor space

B. Ease of installation

C. Maintainability

D. Reliability

E. Energy costs

F. Sustainability – Product Life Cycle

Consider six major criteria


End Suction / Horizontal Split Case and variations

•Inertia base typically extends 6” or more around the pump bedplate

Floor space


Vertical Inline

• Can be suspended in ceiling requiring no floor space

• Can be installed with or without supports

• Space under pumps always accessible for cleaning or maintenance

• Use long radius elbow if space extra tight

Floor space

Supports

No supports


Floor space (500 USgpm/90ft)

End suction (28.5 ft2)

VIL 50% less floor space than end Suction3 pump system: Savings 14.1 ft2 @ $150/ft2 is $2,115

Vertical In-line (14.4 ft2)



VIL 78% less floor space than HSC3 pump system: Savings 51.9 ft2 @ $150/ft2 is $7,785

Horizontal split case(66.0 ft2)



VIL replacing HSC



VIL 66% less floor space than HSC turned Vertically3 pump system: Savings 27.6 ft2 @ $150/ft2 is $4,140


Horizontal split case(42.0 ft2 vertically mounted)


VerticalIn- Line


VIL 60% less floor space than HSC (top suction top discharge)3 pump system: Savings 21.6 ft2 @ $150/ft2 is $3,240

Horizontal split case(36.0 ft2 top suction and discharge)



Vertical In-Line pumps typically use 1/4 floor space of equivalent HSC design units

Floor space

Consultant – Flack + Kurtz inc.

Battery Park, New York City –Installed in the 80’s


Floor space

1/4 floor space

HICSA MexicoDesign Built Contractor

Ford Plant, Mexico


Floor space

Southern AirDesign Build Contractor

Presenter

Presentation Notes

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?


Floor space

Enwave, Toronto –16x16x15 350hp(400-375 250kW)

TMP Toronto


Floor space

Allows for direct connection to equipment:

To chiller To heat exchanger


A. Floor space


C. Maintainability

D. Reliability

E. Energy costs

F. Sustainability – Product Life Cycle


- Vertical – 50 to 78% less


• Coupling re-alignment

• Grouting• Inertia pad• Concrete base• Flex connectors

Ease of installation


Typical costrequired 8” Pump

Inertia base $3660spring mounts

Flex connectors $ 500

Grout and alignment $1600

Extra cost to install $5,760

Ease of installation:Base mounted end suction pump


Ease of installation:Base mounted split case pump

Typical costrequired 8” Pump

Inertia base $5,740spring mounts

Flex connectors $500

Grout and alignment $2,100

Extra cost to install $8,340


Typical cost required 8” Pump

No Inertia Base 0

No Spring Mounts 0 (Base snubbers only forseismic applications)

No flex connectors 0

No grout or alignment 0

Extra cost to install 0

Ease of installation:Vertical In-Line pump


SavingsPiping cost

$225,975 $128,960 $97,015(= 43%)

Length of pipe

2751 ft(2751/100=27.51x3’tdh=82.53’tdh)

1723 ft(1723/100=17.23x3’tdh=51.69’tdh)

1028 ft


Presenter

Presentation Notes

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.


Economical VIL Seismic Mounting



A. Floor space - VerticalB. Ease of installation

C. Maintainability

D. Reliability

E. Energy costs

F. Sustainability – cradle to grave


- Vertical – save > $5,760


Split coupled Vertical In-LineFeatures:

• Critical item is the mechanical seal

• Seal can be replaced in 20 minutes to 1 Hour for an 8” pump

• Rabbet motor fit means no alignment necessary

Maintainability


$8200 annual savingsdue to faster mechanical seal changes

Maintainability:Savings (Edmonton Airport)

Particularly important with Design Envelope pumps

Presenter

Presentation Notes

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.


• Impeller must be removed and reinstalled to change seal

• Realignment always necessary

• Seal can be replaced in 8 hours (estimated) in 8” pump

• An extra 7 hours or $700

Maintainability:Base mounted


Features:

• 2 seals to maintain and 2 bearings to remove and replace

• Realignment always Necessary

• Inboard seal can be replaced in an estimated 6 hours in an 8” pump

• An extra 5 hours required per seal or $500

Maintainability:Split case horizontal


Features:


• Water leakage problems persist with bottom bearing housing

• Top of casing weighs 225 lbs.in a 8” pump

• Seal can be replaced in an estimated 16 hours in 8” Pump

• An extra 15 hours or $1,500 per seal required

Maintainability:HSC vertically mounted



• Realignment always necessary

• Inboard seal can be replaced in an estimated 6 hours in 8” pump

• An extra 5 hours required per seal or $500

Maintainability:HSC top suction, top discharge


A. Floor space - VerticalB. Ease of installation – VerticalC. Maintainability

D. Reliability

E. Energy costs



- Vertical - $500 - $1500 less


The vertical configuration has been proven in thousands of installations for over 50 years

Horsepower is available up to 1250 hp and discharge sizes available larger than 20”

Reliability


Reliability:Armstrong VIL – 1960 / 70’s

• All major competitors have now copied the Armstrong VIL concept for HVAC pumping

• 2180 Yonge installation see pumps circa 1970.

Still relevant for present day –Add Sustainability concerns

Vertical In-Line (VIL) Pump. Circa: 1970


Reliability

Vertical Pump runs vibration free

• hsc highest vibration

Source - Hydraulic Institute 9.6.4-2000

End Suction Vertical HSC

10 hp 0.125 0.125 0.125100 hp 0.175 0.175 0.2

in/sec rms unfiltered


ReliabilityPump runs vibration free

• VIL maximum above pipe, reduces down to casing and then any residual attenuated by piping system

• Horizontal maximum hard mounted to baseplate • Requires inertia base

and springs

Source - Hydraulic Institute 9.6.4-2000


Reliability

Pump runs vibration free

• Rotating motor is above the pump

• Makes Hydraulic Institute vibration requirement

• Flat edge coin will stand on end while pump is operating


Reliability

Atlantic Station, Atlanta –14” (350mm) pumps 450hp (335kW)

Engineer: Barrett, Woodyard & Associates, Inc. (BWA)Design/Build Contractor: Mallory & Evans Inc.


Reliability

University of Miami, Miller School of Medicine –20x20x19 600hp 6P

Engineering Firm: Newcomb & Boyd – AtlantaContractor: John J Kirlin – Ft. Lauderdale


Drive Others

Centrifugal PumpsFailure Rate Versus Pump Type Shell Limited

150 –

100–

50 –

0 –

Horizontal Vertical

Vertical In-Line

58%more reliablethan Base Mounted

Reliability

Pump Bearings

Pump ClosurePump Others

Drive Bearings


A. Floor space - VerticalB. Ease of installation - VerticalC. Maintainability - VerticalD. Reliability

E. Energy costs



- Vertical – 58% more reliable


•End suction pumps uses single suction impellers, HSC uses double suction impeller

•VIL uses the same impellers • Single suction to 10”, double suction, double

volute12” to 20”

•Efficiency varies by 0.1 percentage point depending on casing hydraulic turns

Efficiency of the pump types are basically the same

Efficiency


Less pipe = less friction lossresulting in operating cost savings:

$6,600(est. from TDH reduction)

SavingsPipe energy loss 37%

Length of pipe

2751 ft(2751/100=27.51x3’tdh=82.53’tdh)

1723 ft(1723/100=17.23x3’tdh=51.69’tdh)

1028 ft

Energy costs

Pipe Length reduction

Presenter

Presentation Notes

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.


A. Floor space - VerticalB. Ease of installation - VerticalC. Maintainability - VerticalD. Reliability - VerticalE. Energy costs



- Vertical – 37% less pipe loss


Sustainability – Product Life cycle:Carbon footprint

VIL•no house keeping pad

•No inertia base

Required for both end suction and horizontal split case


Sustainability – Product Life Cycle:Carbon footprint

•Carbon footprint of concrete •For typical 8” HSC pump 2

metric tons is used

•160 kgs of CO2

•All the concrete then goes into landfill when the building is demolished


A. Floor space


C. Maintainability

D. Reliability

E. Energy costs

F. Sustainability – Product Life cycle


- Vertical- Vertical




Values escalate exponentially with integrated controls


A. Floor space


C. Maintainability

D. Reliability

E. Energy costs

F. Sustainability

Vertical


Design Envelope Vertical Inline Pumping

Presenter

Presentation Notes

This presentation will explain how the new Armstrong Design Envelope pump range delivers benefits to all stakeholders in a building through its life, from concept, detailed design, installation, commissioning and through its operating lifespan, covering multiple changes of use and maintenance needs. We will start by explaining the need for Design Envelope technology. Next, we will talk about the key components of a pump, allowing us later on in the presentation to understand the benefits that Design Envelope pumps deliver. Then, you will see the huge cost and operational benefits that accrue by applying best practice control to variable speed pumps. We’ll start by looking at past and current conventional control methods. This will help the understanding of how Design Envelope pump’s automatic pump speed control dramatically reduces whole life cost.


The three fundamental Design Envelope elements

• Digital• Integrated

controls• On-board

intelligence• Economical

variable-speed inverters

• Factory configuration

• Modeling• Selection

software• In-house 3D

design• Economical

control logic

Enabling Technologies

Presenter

Presentation Notes

Technologies that enable Design Envelope today which have not been available in the past are Digital Integrated controls On-board intelligence Economical variable-�speed inverters Factory configuration Modeling Selection software In-house 3D design Economical control logic



• Demand-based control

• All variable load/speed

• Plug and play BMS-ready/-independent

• Sensorless / Sensoring

• Commissioning by controls, self-regulating / continuous commissioning

• Automatic data/metering

• Internal diagnostics (incl. data storage)

• Increased “sweet spot”

Design Envelope Capabilities









control logic


Presenter

Presentation Notes

Capabilities which accrue to the customer from sign Envelope technologies are 1) Demand-based control – Enables equipment output to be varied dependent on system requirements. No PID loops are required to achieve proper output. The equipment provides only the amount of cooling or heating required by the space – no instances of over shooting or wasted energy. 2) All variable load/speed – Enables varying equipment output by slowing down or speeding up dependent on system demand. The equipment provides only the amount of cooling or heating required by the space – no instances of over shooting or wasted energy. 3) Plug and play – The equipment electronically tunes itself to the system right from the get go without mechanical adjustments. Start –up calibration assures users that the equipment is properly set up for the lowest energy use. 4) BMS-ready / independent – Equipment which works with or without a central building management system. Equipment installation becomes easier resulting in rapid installation and commissioning. 5) Commissioning by controls – Eliminates the need for mechanical adjustment to optimize the system and verify the operating point.Elimination of specialised contractor personnel to co-ordinate multiple pieces of equipment in order to achieve specified performance. 6) Self-regulating / continuous commissioning- is able to operate independently or networked. Changes to the occupant profile do not require system changes. The system continuously adjusts to changing systems over time resulting in a tremendous savings in life cost. 7)Automatic data/meter reading – Ability to accumulate operation data which can be analysed both by the intelligence in the equipment itself as well as remotely to optimize operation. 8)Internal diagnostics (incl. data storage) – ability to assess equipment performance at total-system or individual-device levels which results in Improvement of long term building performance and early detection of operational issues> 9) Increased efficient capacity/ “sweet spot” - provides a large area of efficient operation rather than a single design point for maximum load. Equipment flexibility reduces need for reworks and customizations resulting from differences between design and real world conditions 10) Match-up of internal components and harmonization of external equipment - pairs up highly compatible components and further fine-tunes the interplay of components electronically. Matched and optimized components ensure optimal energy performance. Externally Design Envelope solutions leverage unmatched system components together.



• Pumps• Domestic Water

Boosters• Integrated Plant

Package• Modular Boiler

System• Intelligent Fluid

Management Systems

• Circulators

Design Envelope equipment









control logic


• Demand-based control

• All variable load/speed• Plug and play BMS-

ready/-independent• Sensorless /

Sensoring• Commissioning by

controls, self-regulating/ continuous commissioning

• Automatic data/metering

• Internal diagnostics (incl. data storage)

• Increased “sweet spot”

Design Envelope Capabilities

Presenter

Presentation Notes

Design Envelope solutions from Armstrong include Pumps Domestic Water Boosters Integrated Plant Package Modular Boiler System Intelligent Fluid Management Systems Circulators (future)


London Heathrow

Los Angeles

Bahrain

Toronto Canada

Berlin Germany10%-60% of design load 90% of the time

Worldwide

Design Envelope selection methodHVAC is a global part-load industry

Presenter

Presentation Notes

The HVAC industry recognises that although global temperatures may be rising, the demand for heating and cooling are a fraction of peak load for most parts of the year. The data on the graph shows that whether the climate be temperate in Europe, continental in Toronto, Mediterranean in Los Angeles or sub tropical in Cairo, demand rarely hits peak load. The challenge for the industry has been to design, develop and operate systems that adjust their outputs to part load situations without losing efficiency. This presentation will show how Design Envelope can deliver this promise.


Traditional pump with design point to the left of BEP

Design Envelope pump with design point to the right of BEP

Design Envelope selection is often smaller and in a typical example saves 7% in pump cost and 9% in energy costs

Design point 72% 68%

Average load 68% 74%

100 mm pump 80 mm pump

Traditional Variable Speed Design Envelope

η %η%

Design Envelope solutionSelections save energy and cost

Presenter

Presentation Notes

But before we do so, we must first understand why, when pumps are going to operate at part load for most of the time, pump selection practice must change. Traditionally, pumps are selected so that the design point is at or near to the pump's best efficiency point. This makes sure that if a pump operates at this point all the time, then power consumption is minimised. But variable speed pumps rarely operate at full load. So Design Envelope pumps are selected with the Design Point to the right of best efficiency point. The result is that it’s likely that a Design Envelope pump may have a smaller nominal bore size than a conventionally sized pump. In the illustration on the slide, an 80mm Design Envelope pump is contrasted with a 100 mm conventional selection. At Design Point, the Design Envelope pump is 4% less efficient. But at 50% of design, the 80mm pump is 6% more efficient. Given the typical load profile that variable speed pumps live though, the 80mm selection will consume less power through its operating cycle.


Equipment design envelopes

Preferred Envelope

Design EnvelopeEase of selection

Presenter

Presentation Notes

When Design Envelope pumps are selected in Armstrong’s Ace software, you can look at a range of performance envelopes and decide which envelope suits your likely present and future needs. Again, this reduces risk, helps avoid budget overruns and can make future duty changes cost free.


Take the Load Off


Design Envelope – Sensorless Control

Presenter

Presentation Notes

If equipped with the IVS Sensorless feature, the pump’s performance curves against power and speed are pre-programmed into the controls. During operation, the power and speed of the pump are monitored, enabling the controller to establish the hydraulic performance and position the pump’s head-flow characteristic to the system requirements. As the building’s control valves open or close to manage load, the IVS Sensorless controls can intelligently slow down or speed up the pump to maintain the pressure setpoint. The built-in PID controller converts the pressure setpoint to head. Head squared is proportional to flow, flow is proportional to speed.


Hea

d

Flow

Pow

er

12

S1

S2

Original System Curve

S1 System Curve

S2 System Curve

P1P2

Operating point is wherever pump performance curve intersects system resistance curve

TraditionalSensorless ControlOperating point is where pump performance, system resistance and control curves converge

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?

Sensorless control - Detailed

Presenter

Presentation Notes

The slide is illustrating a system friction design curve [S1 System curve] A pump performance curve at full design speed (S1) is selected to intersect the system curve at the design flow and head conditions. The corresponding power drawn is shown below the performance curves. The control curve is set via the IVS102 graphical interface device by the input of the design flow, head and minimum system pressure (On the vertical [y] axis). As the building conditioned spaces reach the high tolerances levels for the set point conditions, the system 2-way control valves will modulate closed, increasing the resistance to flow and creating a new system resistance curve (Similar to the S2 System curve). This will cause the pump to move left on the S1 performance curve (1), and will pump less water because of the valves throttling to a higher pressure. As the operating point begins to move left, will immediately take less power (2) than the original operating conditions and the Sensorless Control logic recognizes that this power reading is incorrect for the current operating speed and thus reduces the motor speed (Pump curve S2) until the system curve (S1), power (P2) and speed (S2) converge on the control curve. The unit will operate at the new operating point (2) at the reduced power (P2) until the control valves react again to conditioned space environment change and modulate appropriately. Thus the IVS Sensorless Controlled pumping package will react in an identical manner to a pump controlled by feedback from a remotely mounted system DP sensor, without the need to purchase, install and wire the remote sensor. Would you like to see the move from (1) to (2) in more detail?


Original System Curve

System has CV modulating closed resulting in a steeper S2 system curve

Speed is stable at 1 until system control valves (CV) modulate.

1

2

S1

S2

S1 System Curve

S2 System Curve

Reverses as CVs open

Flow (gpm)

Head (ft)

Power (bhp)

Freq.(Hz)

1000 80.0 25.2 55.3

900 70.9 19.8 51.2

Constant speed900 88.0 23.8 55.3

Sensorless data

How we get from 1 to 2S2 System Curve

Sensorless control - Detailed

Presenter

Presentation Notes

This slide has zoomed in on the previous slide and illustrates a system friction design curve [S1 System curve] A pump performance curve at full design speed (S1) is selected to intersect the system curve at the design flow and head conditions. The corresponding power drawn is shown below the performance curves. As the system 2-way control valves modulate closed, the system resistance increases to create the S2 System curve. This will naturally cause a centrifugal pump to move left on the S1 performance curve to the new system flow. With the example system a constant speed pump will move all the way to the new position at the same speed (S1) and will take less power as shown on the slide (5% savings). HOWEVER the Sensorless control program behaves in a completely different manner. With Sensorless Control immediately the system curve moves from the steady state, the program recognizes the change in power and immediately adjusts the speed to maintain the operating point on the control curve. It will continue in this manner until equilibrium is achieved when the control valves stop modulating. Resulting in a >21% energy savings … more than 4-times the savings from riding the pump curve. Similarly should the CVs open the operating point would move to the right along the control curve until the valves stopped modulating.


Integrated Sensorless control – Values and benefits: Operating cost saving opportunities

Power Energy Savings

32.03 Incremental CumulativeConstant speed throttled

Reduced speed unthrottled –constant flow

Reduced constant speed –variable flow

Variable speed –variable flow –Mech. Room Sensor

Integrated Control Sensorless

27.11

19.36

7.32

14.35

15%

29%

49%

26%

15%

40%

77%

55%

A

B

C

D

E

Based on 6” 40hp unit

Exceeds ASHRAE 90.1 requirements

Presenter

Presentation Notes

This slide goes well beyond our discussion so far and introduces the simplified powerful energy saving of the Sensorless Control as the final step in a series of energy saving opportunities that could be used independently as the constant or variable nature of the system pump and flow characteristics are understood. Design Envelope pumps are suitable for ALL HVAC applications. Design Envelope trumps all other strategies, even 3-way valve system may be made 2-way with closing the bypass valves and Design Envelope will have a very short payback. Point (A) is the normal situation for most of today’s installed HVAC systems which use constant speed pumps operating in 3-way valve systems. The overflow caused by over-sized pumps is throttled to the design flow. Many such systems could take advantage of installing variable speed pump controls, opening the throttling valve and operating at a lower speed to achieve design flow. Point (B) This would save 15% to 20% of the full flow energy usage. If the 3-way valves were to be converted to 2-ways valves in the same system, the variable flow would ride the pump curve to Point (C) at 50% load. This may cause CV authority problems by the higher pressure of throttled constant speed pumps; however it would save perhaps another 30% by riding the pump curve. We’ve now returned to our earlier discussion. Point (D) represents the pump speed at 50% load when the feedback sensor is installed locally in the mechanical room. This saves about another 25% energy and will help prevent CV problems caused by the higher pressure of throttled constant speed pumps Another 50% energy reduction is obtainable if one properly installs a feedback sensor at the most remote load in the highest pressure loss piping loop and select the pump properly to take advantage of the opportunity OR selects and installs an Armstrong Design Envelope IVS pumping unit with integrated Sensorless controls; which will automatically achieve these energy saving immediately wired and the auto-button pressed on the controls. This will typically exceed ASHRAE 90.1 2010 energy saving requirements.


Integrated Pump SystemsDesign Envelope Pumps For Every Application

Integrated Plant Control

IPC9511

IPC9521

Integrated Pump System controller

IPS4000

ARMSTRONG


Integrated Pump SystemsSome Key Definitions

Primary Only Systems (CPF & VPF)

Primary Secondary Systems (CPVS, VPVS)


Integrated Pump SystemsObjectives

•Occupant Comfort

•Energy Savings

•2 way or 3 way valves

•Pumps provide a head pressure for valve authority on flow control

During part load operation

•Reduce pump energy with variable flow and pump speed

•Improve system delta T for performance of other equipment


Integrated Pump SystemsConverting 3-Way Valve Constant Flow Systems

An Easier Implementation•IPS4000 pump control can adjust based on return temperature zones to regulate pump speed.

•Pumps can be made variable flow based on return temperature signal

•Flow and system dP received from Design Envelope pumps

•NOC received from BMS


Integrated Pump SystemsConverting 3-Way Valve Constant Flow Systems

CHW reset Implementation

•IPS4000 pump control can adjust based on temperature difference of zones to regulate pump speed control.

•Flow and system dPreceived from Design Envelope pumps

•NOC received from BMS


Integrated Pump SystemsIPS4000 3-way Valve Conversion Economics

Design Day Load 450 ton design day% ann avg load 45 %% delta T maintained 80% %INR / kW-hr 7 INRsystem head 80 ftdesign delta T 6.67 deg Cdesign flow 900 usgpmAnnual hours 7000 HR/YEAR# duty chillers 3# of duty pumps 3


Integrated Pump SystemsIPS4000 3-way Valve Conversion Economics

Pump Power Draw (kW) at % Load Operating point


Integrated Pump SystemsIPS4000 3-way Valve Conversion EconomicsAnnual Energy Consumed (kW-hr) at % Load Operating point

• Pump speeds are lower

• Valve position are giving better authority and less resistance

• Pumps operate at a more efficient point on their curves


Integrated Pump SystemsIPS4000 3-way Valve Conversion EconomicsPump Energy Analysis

base case IPS4000 Savings Savings3-way valve Temp Control Percent

CS pump VS pumpkW-hrs 96304 46608 49696 52%INR INR 674,131 INR 326,257 INR 347,874 Chiller Savings at 0.9 kW/ton

base case IPS4000 Savings Savings3-way valve Temp Control

CS pump VS pumpkW-hrs 24651 11930 12721 52%INR INR 172,559 INR 83,513 INR 89,046 TOTAL PLANT SAVINGS

base case IPS4000 Savings Savings3-way valve Temp Control

CS pump VS pumpkW-hrs 120956 58539 62417 52%INR INR 846,690 INR 409,770 INR 436,921

Retrofit Project INR 800,000

Payback Period on 450 ton plant <24 months


Integrated Pump SystemsTwo Way Variable Flow with dP Zone Sensors

•Differential Pressure (dP) sensors placed at greater than 2/3rd, or at end of distribution

dP•After balancing of the system, dP zone setpoint(s) set for design day load

•What if the contractor installs at the mechanical room pump discharge

dP


Parallel Pump StagingBest Efficiency Staging versus Speed Based Staging

0%

100%

20%

40%

60%

80%

FLOW

HEA

D

EFFI

CIEN

CY

POW

ER

1P EFFY 2P EFFY 3P EFFY

0%

100%

20%

40%

60%

80%

FLOW

HEA

D

EFFI

CIEN

CY

POW

ER


ARMSTRONGBESTEFFICIENCYSTAGING

SPEEDBASEDSTAGING

Presenter

Presentation Notes

When adopting a parallel pump approach it is important to consider the staging methodology for the pumps. This slide shows two different methods, Armstrong’s best efficiency staging approach where pumps are stage on and off based on best efficiency and the traditional approach of staging based on pump speed. The latter is typical of BMS control where pumps are staged on around 95% of full speed and off at 55% speed. Clicking through the animation shows the energy impact of delayed staging in the traditional approach where the efficiency has fallen off before the next pump is staged on. The late stage off with BMS systems has similar performance impact.


Parallel Pump StagingEnergy Performance Implications of Speed Based Staging


SPEED BASED STAGING

Energy Savings:3 x 30kW Pumps

Operating Cost* –Speed Based Staging~ $30,371

Best Efficiency Staging~ $20,092

34% Saving

*Based on $0.10/kWh – 12 months operation – 40% design head min pressure

= Areas of highest inefficiency

Presenter

Presentation Notes

Over-laying our building load profile shows that the areas where underperformance occurs with BMS approaches is actually where the building spends most of time in operation! Considering a simple example, the use of Armstrong best efficiency staging can save 34% of the energy consumed in BMS parallel pumping schemes.


Armstrong Design EnvelopeParallel Sensorless Pump Control* (PSPC)•For customers requiring parallel

pump control [Up to 4 motors]

•No control panel or building automation control fees required

•Parallel Sensorless Pump Controller integrated on one unit only. (Interchangeable)

•dualARM units (Illustrated) are wired at factory. Single pumps will be ‘daisy-chain’ wired on site

* Patent Pending

Presenter

Presentation Notes

Bullet points … ON board controller controls all pumps. Receives power from all pump so it’s OK if one pumps fails; even the one it’s mounted on. If the pump it’s mounted on needs to be taken away, the (24V) wiring can be pulled from the controls and the controller left in place on a convenient location. Sitting or taped on / to a pipe. If preferable, the controller can be easily moved to another end-pump with minimum fuss – wiring is simple and tapped holes are on all controls bracket to receive the PSPC. This is a patent pending technology so customer’s will need to buy the panels or BMS staging if they don’t own the PSPC



•What if the contractor installs at the mechanical room pump discharge

dP

•IPS4000 controller can apply a quadratic control curve to emulate the remote sensor, and get the extra energy savings at part load operation to comply with 90.1


Flow (000s) gpm

Head (ft)

dP setpoint at exit of mechanical room

IPS4000 Quadratic Control Curve withMR Sensor


•IPS4000 controller quadratic control curve, exceeding 90.1


Integrated Pump SystemsIPS4000


Integrated Pump SystemsSensorless Speed Control with IPS4000

•Simple on screen setup to adjust as built design flow and head parameters

•Parallel Sensorless Pump Control staging points automatically recalculated for the as built entered condition (no modifications at the pump)


Floor Space

Qty 4 4300 20x10x19 c/w 125 hpintegrated controls 10000 gpm @ 30 ftheadQty 4 4300 14x14x15-60 hp 3650 gpm @ 43 ftQty 4 4300 14x14x15-600 hp 10000 gpm@180ft

Foot print Vertical inline = 830 sq ftHSC = 2600 sq ft


Ease of Installation

• No base – 148 metric tons of concrete

• No flex connector• No support under the


Energy Costs and Sustainability Integrated approach for pump

balancing Controller used for soft start vs

across the line on 600 hp


Enwave – Case StudySummary

A. Floor space - Vertical – 68% lessB. Ease of installation - Vertical – save > $150,000C. Maintainability - Vertical – $5,200/year lessD. Reliability - Vertical – more reliableE. Energy costs - Vertical – less pipe lossF. Sustainability – Product Life Cycle - Vertical –

26,640 lbs of CO2 less


Achieving 189.1 Through Integrated Plant Control


Agenda

1.Overview of Standard 189.1

2.Long term 189.1 objectives

3.A Net Zero road map for chilled water plant solutions

4.Demand based Integrated Plant Controls and 189.1


Standard 189.1 - What is it About?

• Standard for the design of high performance green buildings

• A compliance option of the international green construction code

• Minimum for high-performance, green buildings

• Applies as per ASHRAE/IES Standard 90.1

• Optional compliance path to the International Green Construction Code

• Not a design guide or a rating system


189.1 Standard for High-Performance Green Buildings

Purpose

EnvironmentalResponsibility

Resource Efficiency

OccupantComfort

CommunitySensitivity

While meeting the needsOf the present, without

Compromising the abilityOf future generations

Balance

Today

Tomorrow


189.1 Application

• Is Voluntary

• Can be adopted as law

• Draws from ASHRAE 62.1 and 90.1

• Applies to the building design, construction and life

• “prescriptive” or “performance” based


189.1Standard Topic Areas

Sustainable Sites

Water Use Efficiency

Energy Efficiency

Indoor Environmental Quality

Building’s Impact on the Atmosphere, Materials & Resources

Construction and Operations Plans


189.1Relative to Existing Standards

•Original Standard 189.1-2009 goal 30% lower than Standard 90.1-2007 INCLUDING PROCESS

•Standard 189.1-2011 goal 5-15% lower than Standard 189.1-2009

•Appendix G from Standard 90.1 is incorporated as a Normative Appendix


189.1Where Integrated Plant Control Contributes

Sustainable Sites

Water Use Efficiency

Energy Efficiency

Indoor Environmental Quality

Building’s Impact on the Atmosphere, Materials & Resources

Construction and Operations Plans


189.1More Aggressive Net Zero Agenda

Energy Reduction Proposal

0

20

40

60

80

100

120

2010 2015 2020 2025 2030 2035

Ener

gy D

ensi

ty

Standard 90.1

High Performance 189.1


189.1Not All Buildings can reach net Zero

ZEB Floorspace % By Segment

0102030405060708090

100W

areh

ouse

Rel

igio

us W

orsh

ipR

etai

l (no

n m

all)

Educ

atio

n

Serv

ice

Publ

ic A

ssem

bly

Aver

age

Hea

lth C

are

(out

patie

nt)

Offi

ce

Lodg

ing

Food

Sal

es

Labo

rato

ryPerc

ent O

f Flo

orsp

ace

able

to

mee

t Net

Zer

o

High Percentages

Low Percentages


Achieving 189.1 Through Integrated Plant ControlWhere we can go with HVAC chilled water systems and how that compares to our net zero building goals

Energy use

Renewableenergy

Ener

gy

consu

mpti

on

Time

Renewable energy source sufficient to meet building energy demand


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n

Variable flow design

HVAC systemChiller plant

Variable secondary flow plants (30% today, and 90% installed base)

Net Zero CHW Solution Roadmap – Starting Point


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary


Net Zero CHW Solution Roadmap

Variable Primary Chiller Plants with Variable Speed Chillers


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary

Demand Based All-variable Control (IPC)



Demand Based All-Variable Chiller Plants


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary

Demand based all variable

Intelligent devices



Intelligent Devices


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary


Intelligent devices

Ground sourced



Ground Source Solutions


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary


Intelligent devices

Ground sourced

Chilled beams



Chilled Beams


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary


Intelligent devices

Ground sourced

Chilled beams Low loss distribution



Low Loss Distribution


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary


Intelligent devices

Ground sourced




Demand based all-variable chiller plant automation

Energy Efficiency

Renewables


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary

Demand based all variable plant automation

Intelligent devices

Ground sourced




Demand based all-variable chiller plant automation

Energy Efficiency

Renewables

25-50%


Plant Annual energy Savings of

30-60%

Design Envelope Integrated Plant ControlThe Benefits of Optimization

Annual Water Savings on the

Cooling Tower of 4-7%Longer Plant Equipment Life,

20-30%Protect your ROI with ECO*PULSE On-board Diagnostic Service

saving 5-20% annual energy costs

kW-hr

30-60%

$

H2O

4-7%

$

Life

20-30%

$

ROI

5-20%

$


Existing practice(CPVS)

Analog eraFeedback loop (PID)Silo sub-system controlVS chillers, variable secondary CW reset0.76 kW/ton (COP 4.7)0.78 kW/ton (COP 4.6)0.72 kW/ton (COP 4.9)

Existing best in class

Analog eraFeedback loop (PID)Silo sub-system controlVariable primary flow (VPF) with CHW & CW reset0.72 kW/ton (COP 4.9)0.75 kW/ton (COP 4.7)0.68 kW/ton (COP 5.2)

Design Envelope integrated demand basedDigital eraDemand based relationalIntegrated plant solutionAll-variable chiller plant

0.50 kW/ton (COP 7.1)0.56 kW/ton (COP 6.3)0.48 kW/ton (COP 7.4)

ModerateHumidAridPl

ant

effi

cien

cy

New Variable Speed Chiller Plants

>.76 kW/ton >.72 kW/ton <.50 kW/ton

Armstrong’s Chiller Plant Optimization


More Than90% of Time

Spent at Part load

Comfort Cooling Is A Part Load Application

Presenter

Presentation Notes

This control methodology is predicated on two facts. The first fact is that comfort cooling is a part load application. Regardless of the city or country that a plant designer is addressing, the plant must be sized to accommodate what we refer to as “design day”. This “design day” cooling load occurs maybe for 15 – 30 minutes every year. The majority of the plants operating hours are spent at some fraction of the plants design day capacity.


Design Envelope Equipment Operation In A Part Load Application

Design Envelope Solutions are designed for BEST EFFICIENCY operation here

Traditional Designs were optimized for operation at full load

Presenter

Presentation Notes



Variable Speed Devices AreMore Efficient At Part Load By Design

Different Performance CurvesDifferent Method Of Control

New PerformanceCurves:

•Variable flow cooling towers•Variable speed pumps•Variable speed air handlers •Variable flow chillers

Presenter

Presentation Notes



Traditional chiller plant controlprocess set-point based

BMS

Capacity basedsequencing

Automation Sequence

Parallel equipment staging (up/down)

Equipment speed control

Silo sub-system control

PID feedback control loopsAmbient reset

TraditionalLogic

Presenter

Presentation Notes

What if the BMS did not look a the system as items of equipment that it enables and controls to a given set of pre-determined instructions. What if it viewed the system as a whole and understood the power relationships, physcometry and linked all this into the actual needs of the building. What if it based the sequencing and operating point of the equipment based on the actual needs of the building demand (we d this on the secondary side with DP control etc, but generally do not use this same theory on the primary plant control). Rather than a set point temperature. What if we actually looked at the performance curves for the equipment within the system and moulded these together to offer a overall increased performance. If you need an analogy discuss racing cars (tyres, suspension, aerodynamics etc) or a cycling peloton


Armstrong Design Envelope Integrated Plant Control

Performance Curve Based

Heat Transfer and Power Consumed

demand with power relationships

View Equipment As Performance Maps: Tons of cooling (kWc), and Electrical Power

IPC

Presenter

Presentation Notes



BMSIPC

Two different system philosophies

Component based System based

Presenter

Presentation Notes



Building Cooling Demand (tons kWc), for Power In with target delta T

Presenter

Presentation Notes

Basically ‘What If’ the plant controller or BMS looked at the system in its entirety and looked at the nett output result from the performance of the system rather than the individual items of the plant. What if there was more inelegance to be ad from equipment and sensors already installed. Could we not then control the plant in a more symbiotic way, trading off performance in one part of the system with the nett result that te system itself operates at a higher overall efficiency.


Natural curve sequencing vstraditional capacity based

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Ove

rall

Syst

em C

OP

% Chiller Load

Natural Curve Sequencing

VS ECWT 13°C

VS ECWT 18°C

VS ECWT 24°C

VS ECWT 29°C

55F65F75F85F

CapacityBasedIPC

Presenter

Presentation Notes

This brings us to the first element of our control methodology, “natural curve”. The natural curve is defined as the line that joins the best efficiency point for each of multiple scenarios, in this case the scenarios are 4 different entering condenser water temperatures. Natural curve sequencing says that parallel equipment, in this case parallel chillers, should be sequenced such that they operate a close a possible to the natural curve. So, if we had a plant with 3 parallel variable speed chillers and the plant was operating at 33% load with 19C entering condenser water, and we sequenced the chillers using traditional capacity based sequencing we would be operating one chiller, on the blue line at 100%, which would be a chiller efficiency of 0.4 kW/ton. If we applied natural curve sequencing we would operate 3 chillers at 33% each, for a chiller efficiency of 0.3 kW/ton, with a net efficiency gain on the chillers of 25%, just be using a different sequencing methodology on the same mechanical equipment. I can’t stress how much this goes against tradition. The main point being that mechanical operators have always thought to minimize the number of pieces of plant equipment operating because they are thought to be more efficient at full load, and starting other equipment would prematurely wear the plant down. For part load applications, we move from the top right to the bottom left.


Natural curve sequencing vstraditional capacity based

Chiller 1 (lead) - 40% Chiller 2 (lag 1) -40%

Chiller 3 (lag 2) – 40%

Chiller 1 Chiller 2

Chiller 3

0%

100%

20%

40%

60%

80%

Presenter

Presentation Notes

This sequence shows the chillers loading up based on natural curve principles such that the chillers spend as much time at or around the peak efficiency point as possible. In this scenario, at 60% cooling load with all three chillers operating at 40% of capacity, very close to their peak efficiency, chiller COP will be above 11.0. A 40% increase in chiller efficiency….!!! The other thing we can do is to remember that our system has been designed on a 5 or 6 deg delta T, we can now start to slow down the primary chilled water (the kW cooling load remains the same) flow through the evaporators or even allow the chilled water leaving temperature to rise. Slowing the pumps down to match the load will run the compressors longer (or maybe even continually) but any increase in consumption through the compressor may be offset by the pumps. Increasing the CHW set point would again reduce the load on our system (not as much de-suerheat) and have minimal effect on the overall system dynamics (i.e maintain the return temperature).


Natural curve tower sequencingapproach temperature effects

Lower the leaving tower water temperature with:

- Natural curve sequencing,

- Variable flow towers, and

- the same or less power

deg C14

11

8

6

3

Natural Curve Sequence Of Towers

0

5

10

15

20

25

33% at 56F, 13C 66% at 65F, 18C 100% at 77F, 25C ETW

App

roac

h Te

mpe

ratu

res

(deg

F) a

t Ide

ntic

al F

an

and

Pum

p Po

wer

Capacity SequenceNatural Curve

333231

33% 66% 100%

Presenter

Presentation Notes

Tower ETW Approach Temperature For 3 Tower Systems Now lets take a bigger perspective and see the impact of natural curve sequencing on the “all variable speed” plant, not just the chiller as a stand alone device, and compare this to a traditional capacity based sequenced plant with constant flow cooling towers. The chart displayed shows the approach temperature for a 3 chiller plant with a design wet bulb temperature of 77F at design day load. The approach temperature for the capacity sequenced constant flow cooling tower is shown by the read bar, and the approach temperature for the all variable speed plant with natural curve sequencing is shown by the green bar. On design day the approach temperature for both plants is approaching 50F. The approach temperature of the cooling tower is defined as the difference between the entering tower water temperature and the ambient wet bulb temperature. So on design day the entering tower water temperature is 95F water coming to the cooling tower from the chiller. Now, on a 2/3rd load day the capacity sequenced plant will destage one chiller and destage one cooling tower. Operating with 2 chiller and 2 cooling towers at 100%, this configuration has the same sqft of tower surface area per kW load of cooling effect as was present on design day. The ambient temperature on the 2/3rd load day however will be cooler, and as the air temperature is cooler, it has less moisture capacity than the design day air temperature, and as a result the evaporative effect of the cooling tower is not as great as it was on design day and the approach temperature of the towers will go up. With the all variable speed plant, and natural curve sequencing, we will keep all three cooling towers and chillers running, but just slow them down to meet the new load point. In this configuration we are leveraging the full cooling tower design day surface area, and keeping it all active for maximum evaporative effect at part flow. The result is that we are actually able to reduce the approach temperature and we have almost a 3C approach temperature advantage over the capacity sequenced plant. This effect is even more favorable on a 1/3rd load day, where the wet bulb temperature is shown as 13C. Now lets consider the effect of this on the chiller.


IPC

Speed controlDemand based power relationships (not set-point PID feedback loops)

Presenter

Presentation Notes

An old fashion PID control loop was based on set points controlling 3 loops (chilled water loop, condenser water loop and refrigerant loop). Each loop used different set points and for example, the chilled water loop was controlled using DP reading across control valve, refrigerant loop was controlled by the chilled water leaving temperature while the cooling tower loop was controlled by the ambient temperature set point. This kind of control strategy posed difficulty in controlling multiple set points and matching these setting with constantly changing building demand for cooling. As mentioned before, the chilled water plant rooms are being controlled the same way as they have been for the past 30-40 years, and this illustration explains one of the core issues around that missed opportunity. Primarily, our chilled water plants are operated as three separate sub-systems, a PID feedback control loop for the CHW distribution system, and PID feedback control loop for the chiller, and a third PID feedback control loop for the condenser water. Each of these three “sub-systems” performs as efficiently as it can without consideration of how their operation effect the efficiency of the neighboring other two systems. The plant is definitely not an integrated system. Lets now look at performance that is possible from an all variable speed plant with the IPC 11550 control system compared to today’s standard practice.


Design Envelope Integrated Plant ControlPatented Control Technology

Capacity basedsequencing

Natural curvesequencing

Automation element

Parallel equipment staging (up/down)

Equipment speed control

Silo sub-system control

PID feedback control loops

Ambient reset

Equal marginal performance principle

Demand based control

Traditional Demand based

Presenter

Presentation Notes

The Hartman LOOP is comprised of three new control methodologies; natural curve sequencing, equal marginal performance principle, and demand based control. The Hartman LOOP is a control methodology that is still relatively new, it was first introduced to the market place about 8 years ago, and is now in operation on more than 20 chilled water plants around the world with very positive results. The majority of the plants that it was installed on are operating with COPs of greater than 8.


Armstrong solutions: two configurations

Integrated Plant Control For New

Projects

Optimization Modules For Retrofit Projects

Presenter

Presentation Notes

Armstrong offers 2 configurations within this family of plant automation solutions We offer a plant level solution, the IPC 11550, and a building automation level solution, the OPTI-VISOR The IPC is a full plant automation solution that communications directly with the mechanical gear and instrumentation, and takes responsibility for the control instructions to the devices. The OPTI-VISOR control panel is an “advisor” to the existing building management system on how to optimally run the plant, best fan speed, best pump speed, etc. The BAS remains responsible for the automation of the plant equipment and receiving data from instrumentation Both work on the all variable speed plant configuration and provide impressive paybacks on new project and retrofits


• Full plant automation• Remote Access• BMS Read/Write• Email alarms• Equipment Data• User Friendly Interface• 10 Year Data Capacity• Factory Built & Tested

Design Envelope Integrated Plant Control System

Presenter

Presentation Notes

The default screen, or screen saver is a performance screen for the complete plant, and each of the main pieces of equipment in the plant. This screen serves as a terrific training tool for the operator to observe the efficiency gains made by operating the plant in auto mode. If the operator feels that he can do better, the operator can observe how big the efficiency gain is in auto mode compared to manual mode. The IPC 11550 ushers in a new era of user friendliness with a number of firsts. Like many other system schematic displays, the IPC has icon driven control that enables the user to simply touch the symbol on the screen and bring up a status display. From the status display for that equipment, in this case we are showing a VIL pump, the operator can gather operating data and limits for that device. IN addition, the operator can change the operating status of that equipment, for example it can be electronically locked our of the duty status rotation by selection the HOA control to the “off” position. The device can be set to duty status 1,2,3 …, or as the standby piece of equipment. The equipment may also be set to a fixed speed, such as 65% FS. More interestingly, the IPC equipment screen has two additional screen buttons titled “nameplate data” and I&O manual. The name plate button will bring up all the name plate data on the screen, saving the operator from having to go down to the plant with a pen and pad to get the information. The I&O button brings up the operating manual in PDF format. All of these functions are 100% available through the security encrypted web access license seats, 4 seats provided with each controller. This enable the operator of multiple facilities the ability to receive a warning by email from our controller, log in and take the suspect equipment out of service to prevent catastrophic failure, and then look up the necessary service parts in the manual to have them ordered for the next day. With more and more facilities have a single operator, this technology enables them to be in two places at once.


Sequences for:

Design Envelope Integrated Plant Control System

• Emergency Power Transfer Switch

• All variable flow (VPF & VPVS)

• Water Side Economizers

• Thermal Energy Storage

• Ground Source (Geothermal)

• Dry Air Coolers (Evaporative mist)

• Compressor Sequencing (large 11 kV dual compressor CS)

• Demand Limiting for Demand Response

Presenter

Presentation Notes

We have developed a new series of control and product solutions that revolve around integrated control, one family of these is our line of all variable speed chilled water plant controls They offer up to 60% energy savings per year on the whole chiller plant, through the factory integration of a new control algorithm. These are robust factory built automation systems specific for a variety of chiller plant configurations, include all-variable speed plants: chillers, tower fans, CW pumps, and chilled water pumps. These are site configurable devices, during commissioning the installer is inputting process data such as number of chillers and capacity of chillers, as opposed to creating any site specific operating code. Important for your business is that they network with building automation systems, and enable remote access for your support of the customer relationship.


• At a glance display

• Intuitive touch-screen interface

• System performance (operating status, setpoints, hardware data, etc.)

• Integrated I&O Files

• Trending

• Data logs

• Alarm history

• Setup and troubleshooting

• Remote monitoring

0.55 kW/TON

Integrated Plant Controller – IPC11550HMI

Presenter

Presentation Notes

The default screen, or screen saver is a performance screen for the complete plant, and each of the main pieces of equipment in the plant. This screen serves as a terrific training tool for the operator to observe the efficiency gains made by operating the plant in auto mode. If the operator feels that he can do better, the operator can observe how big the efficiency gain is in auto mode compared to manual mode. The IPC 11550 ushers in a new era of user friendliness with a number of firsts. Like many other system schematic displays, the IPC has icon driven control that enables the user to simply touch the symbol on the screen and bring up a status display. From the status display for that equipment, in this case we are showing a VIL pump, the operator can gather operating data and limits for that device. IN addition, the operator can change the operating status of that equipment, for example it can be electronically locked our of the duty status rotation by selection the HOA control to the “off” position. The device can be set to duty status 1,2,3 …, or as the standby piece of equipment. The equipment may also be set to a fixed speed, such as 65% FS. More interestingly, the IPC equipment screen has two additional screen buttons titled “nameplate data” and I&O manual. The name plate button will bring up all the name plate data on the screen, saving the operator from having to go down to the plant with a pen and pad to get the information. The I&O button brings up the operating manual in PDF format. All of these functions are 100% available through the security encrypted web access license seats, 4 seats provided with each controller. This enable the operator of multiple facilities the ability to receive a warning by email from our controller, log in and take the suspect equipment out of service to prevent catastrophic failure, and then look up the necessary service parts in the manual to have them ordered for the next day. With more and more facilities have a single operator, this technology enables them to be in two places at once.


Retrofit Impact: Payback Periods as Short as 6 months

SAVINGS25–30%

OPTI-VISOR

Installed on Variable Primary Systems, upgrading to All-variable

Presenter

Presentation Notes

If the BAS is controlling a variable primary flow plant with variable speed chillers the OPTI-VISOR can be used to upgrade the plants performance with an all-variable speed configuration. For other situations, a retrofit of the IPC plant automation system can be applied. Typical energy savings for these two different ranges of scenarios are shown (reference IP retrofit brochure and OPTI-Visor flyer for details) Important for every high performance system is an automated method to ensure the performance of the asset, we have seen that a 20% erosion in plant performance because of contamination in a tower or chiller can cost the owner $40,000 in extra energy costs that could have been avoided if identified and corrected on day 1. Armstrong offers an automated plant health management service for this, called ECO*PULSE


Health Management Service

•Real time diagnostics of plant equipment and operating status

•Assess equipment based on trended performance ratios

•Able to alert to issues before they become a problem or alarm (low refrigerant, clogged strainers, failing motors, vibration, incorrect service calls)

•Provides assessment of predicted, base case and actual performance

•Viewable web site, device views, and quarterly reports

IPC 11550 System

OPTI-VISORTM


Health Management Service

•Staff monitoring of trends, alerts, and assessments

•Phone notification of issues and recommended site investigation

•Assessment of energy impact through non-response

•Real time: assessment for actual conditions (WBT, load, and combination of operating equipment)

Water cooled New Projects

Water cooled Retrofit Projects

Air cooled New Projects

Air cooled Retrofit Projects


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Effi

cien

cy k

W/to

n


Variable primary

Demand based all variable plant automation

Intelligent devices

Ground sourced



DESIGN ENVELOPE Integrated Plant ControlPart of the Net Zero CHW Solution Roadmap

Design Envelope Integrated Plant Control

Energy Efficiency

Renewables

25-50%


• HELPING YOU ACHIEVE 189.1 TODAY

• ENABLING YOUR CUSTOMERS TO TAKE THEIR SITE TO 189.1 IN THE FUTURE, OR ACHIEVE LEED RATINGS TODAY

• BRINGING BENEFITS AT NO EXTRA COST

Design Envelope Integrated Plant Control


Design EnvelopeIPC | New Construction | Sidra Village, Doha, Qatar

IPC Delivers:

On an annual basis 25%energy cost savings

Confirmed by an Independentutility

** 7250 TR, York Chillers

Presenter

Presentation Notes

A long list of savings that adds up to a LCC and a true value based offering.


Integrated plant controls deliver:

On an annual basis

28%energy cost savings

**10,000TR York Chillers

Design EnvelopeOPTI-VISOR™ | Retrofit | Dalma Mall, Abu Dhabi, UAE

Presenter

Presentation Notes



Design EnvelopeIPC | New Construction | Mixed Use Building, Dubai, UAE

IPC Delivers:


** 1150 TR, Clivet Chillers

Presenter

Presentation Notes



Design EnvelopeOPTI-VISOR™ | Retrofit | Jumeirah Group, Dubai, UAE

Delivers:

On an annual basis

21%energy cost savings

** 3000 TR, York, Trane & Carrier Chillers

Presenter

Presentation Notes



Design EnvelopeIPC | New Construction | Markhiya Mall, Doha, Qatar

IPC Delivers:


** 6250 TR, Carrier Chillers

Presenter

Presentation Notes



• VPVS with Variable Condenser Flow• 10,000 TR – Phase 1

• Expansion to 25,000 TR

• LEED Gold Certification

• Energy & Water Conservation

Design EnvelopeIPC | New Construction | Convention Centre, Muscat, Oman

IPC Delivers:


** 10000 TR, Carrier Chillers


Armstrong Fluid Technology

Thank You For Your Attention

Questions?

armstrong fluid technology | ashrae qatar oryx … · achieving ashrae 90.1 and 189.1 with...

Documents