Variable Flow Systems

System Design For Energy Efficient Pumping

Stephen Hart
Managing Director, Frese Limited

Presentation Outline
Introduction Energy & Comfort compromise Seasonal loads Constant v Variable Flow VSP Two port valve Balancing Problem Fluctuating pressure losses in pipework Pressure control Start Point End Point Mid Point Solution Current CIBSE Pump Flow Temperature Pressure OPTIMA PICV Solution At coil Remote Sensor Sensor Polling Power savings Schemes Constant speed DPCV solution PICV solution Power calculations Life Cycle Graph

The Energy & Comfort Compromise

Maintain a comfortable indoor environment
Full load heating on demand Full load cooling on demand Effective ventilation Silent system operation

Reduce system power absorption

Slow motors at low loads Maximise T at all loads Prevent overflows at all times Minimise system resistance

PROBLEMS AND SOLUTIONS

Typical Heating & Cooling Load Profile

100

75

Flow %

50

25

2000

4000

6000

8000

Hours

Variable Flow System

(Start Point Control)
H [%] Pump curve maximum speed Variable system characteristics

Hset

P1 [%]

25

100

Q [%]

Variable speed pump and two port temperature control valves

Q [%]

VSP (Constant Pressure)

Variable Flow System

(End Point Control)
H [%] p Pump curve maximum speed Variable system characteristics

Hmax

Hset

P1 [%]

25

100

Q [%]

Variable speed pump and two port temperature control valves

Q [%]

VSP (Constant Pressure)

Unstable Temperature Control

p p

At PartLoad Full Load Pressure

Underflow

Overflow

Underflow

Overflow Distance

Differential Pressure Control

DPCV Across a Branch

Source: TA

As a rule of thumb, limit DPCV setting to 1.5 times the design P of the index on each branch to secure authority at part load

Differential Pressure Control

DPCV Across a Modulating Valve

Source: TA

Perfect solution ensures authority of 1 on modulating valve but is expensive and adds to pump resistance

Variable Flow System

Pressure Independent Control Valve
p

Maintain minimum required P for PICV and coil at design

Frese OPTIMA PICV

One valve replaces:

Two port modulating valve Automatic balancing valve Differential pressure control valve

Benefits - Design
Less time to define the necessary equipment for a hydraulic balanced system (only flow data is required) No need to calculate valve authority Flexibility if the system is modified after the initial installation

Benefits - Installation
No further regulating valves required in the distribution pipework when PICV is installed at terminals. Total number of valves minimized due to the 3-in-1 design Minimized commissioning time due to automatic balancing of the system No minimum straight pipe lengths required before or after the valve.

Benefits - Operation
High comfort for the endusers due to high precision temperature control Longer life due to less movements of the actuator Less energy consumption due to faster response and increased system stability

MEASURING ENERGY SAVINGS

Calculating Power Absorption

1) H Q 2 2) P H Q P Q3 Q H P = = 2 4 8

or, 20% Q = 36% H = 49% P

Large system constant curve

TP 80-250/2

17

Large system constant pressure

TPE 80-250/2

18

Large system PV & remote sensor

TPE 80-250/2

19

PICV Large System End Point Control

AB

If either A or B do not have the required P then the pump controller will speed up the pump.

TPE 80-250/2

20

Calculating Pump Energy Consumption

100 8760 hours/year 75 Flow %

50

25

2000

4000

6000

8000

Hours

Load profile Calculation profile

TP 80-250/2

TPE 80-250/2

TPE 80-250/2

TPE 80-250/2

Constant Speed DPCV

Hours [%] 6 15 35 44 Flow [%] 100 75 50 25 Pres. kPa 238 253 261 261 Power W 7430 6740 5850 4960

Start Point Control DPCV

Hours [%] 6 15 35 44 Flow [%] 100 75 50 25 Pres. kPa 220 220 220 220 Power W 7030 5800 4800 4040

Mid Point Control DPCV

Hours [%] 6 15 35 44 Flow [%] 100 75 50 25 Pres. kPa 220 191 144 116 Power W 7030 4360 2670 1730

End Point Control PICV

Hours [%] 6 15 35 44 Flow [%] 100 75 50 25 Pres. kPa 154 102 66 43 Power W 4890 2550 1230 554

Total 48815 kWh/year 100%

Total hours: 6.840 hours/year Running 41605 kWh/year 85%

Total 24278 kWh/year 50%

Total 11827 kWh/year 24%

21

Pump Electrical Energy Saving

Variable Flow Systems

System Design For Energy Efficient Pumping
Stephen Hart
Managing Director, Frese Limited