Intelligent Pumping Controls & Energy Optimizations

Distributed Pumping System

Presented by
[Link] Rajkumar, Key Account Manager
srinivas@[Link]
Conventional Chilled Water Pumping System
Balancing Valve Balancing Valve

Common challenges in
Conventional Chilled
Water Systems
Modulating Modulating
Valve Valve
• Balancing and Low ΔΤ
issues
Secondary • Commissioning issues
Pump
• Variance from design
Decoupler Bypass

Chiller Chiller

Chiller Chiller
Primary Pump Primary Pump

Primary-Secondary Primary-Only
What kind of Air-conditioning System we want?

Plug & Play

Design Installation Control Strategy & Commissioning Turning On & Use

Programming Comfort ?
Energy Consumption ?
• No need to know what is Differential Pressure (DP)
Otherwise?
• Where to install DP sensors?
• Minimum commissioning
• Self balancing System • What DP setpoint value to input to DDC?

• No need water balancing

Distributed Pumping System
Distributed Pumping System

ASHRAE Handbook Distributed Pu

Example:
Distributed Pumping System

Unlike conventional pumping

system, no pressure setpoint is
required for the P-CS Pumping
System.

The control program will adjust

the variable primary pump speed
based on whether the supply
water flow is meeting the
demand.

If the supply is too much it will

reduce the pump speed, and if
the supply is low it will increase
the pump speed.
Distributed Pumping System

Distributed pumping is a paradigm shift towards

decentralized pumps instead of central pumps in
distribution networks

By using coil pumps the system is “relieved” from

all the pressure consuming components and
equipped with units that generate pressure only
when and where is needed.
Distributed Pumping System – Case Study
Collaborators

Air-conditioned Area: 3460 m2

Factory Floor Area (partially cooled):
8300 m2
6 units of AHU
2 units of PAHU
2 units of Chillers (1 standby)
- Carrier 30XW552P [572 kW (163 RT)]
2 units of 5 kW Primary Pump
Distributed Pumping System – Case Study
Distributed Pumping System – Case Study
Primary–Only Pumping System Primary–Coil Secondary (P-CS) Pumping System
100% Load

Decoupler

Computer Simulation

= 58 kPa
Pump
Head
• Simulate Pressure & Flow
at all locations in the
piping network
• Simulate Power
Consumption of Pumps
• Simulate Part load
conditions
Distributed Pumping System – Case Study
2016 2017 Removal of Balancing Valve
Nov Dec Jan Feb Mar Apr May
Baseline Data
Collection
Retrofitting &
commissioning
Post-retrofit Data
Collection Installation of Coil Pumps
Data
Analysis

Reduced Primary Pump Size

3 kW
5 kW
Distributed Pumping System – Case Study

• Less Pumping Power

Distributed Pumping System – Case Study
Results
Outdoor Weather (Air-con operation
4-Week Average Outdoor RH
Baseline: 79.4%
periods)
Post-retrofit: 82.1%

Average Temperature - Post-retrofit

period (no significant difference)

Average Relative Humidity – Post-

retrofit period (higher)

Other Influencing Factors

• No change of AHU supply air
setpoints
4-Week Average Outdoor Temperature
Baseline: 30.6C
• No change of room temperature
Post-retrofit: 30.7C setpoints
• No change of office and factory
operations
Distributed Pumping System – Case Study

CHW Pumping Energy Consumption (4 weeks)

Annual CHW Pumping Energy

Savings
= (1727-773) x 52/4
= 12,402 kWh
Distributed Pumping System – Case Study
Larger Temperature Difference (T)

Primary Primary + % Savings

Only (Kwh) CS (Kwh)
CHW
Pumping
Energy 1,727 773 55.2%
Consumption
• Total Chilled Water Produced/Pumped - Reduced
by 30.7%

CHW Pumping EER Original Post-Retrofit

P-Only P-CS
(4 weeks)
(kW/RT) (kW/RT)
Pumping EER 0.059 0.032
Distributed Pumping System – Few more references

• Singapore SAVE PUMP & CHILLER ENERGY

- Temperature : 28⁰C
- Humidity (RH) : 75 % • 32% pump savings (kW/RT)
• ∆T raised by 1,5°C to 6,8°C (design value is 7°C)
• Office Building from 2014

• BCA Green Mark Platinum

• Constant Load profile

• BMS system

• ⁓ 6000 m2 cooling area

• 15 Coil Pumps used

Distributed Pumping System – Few more references
Distributed Pumping System – Few references

Tamara Hotel and Convention Centre ,

Trivandrum
HVAC Consultants – M/s Alex Cyriac, Cochin

Air-conditioned Area: 1,12,285 [Link]

18 units of AHU
3 units of HRW
2 units of Chillers - Bluestar – 220 TR
2 units of 11 kW Variable Primary Pump
2 units of 7.5 kw Condenser Water Pump
48 units of Coil Pumps
Distributed Pumping System – Few references

Primary Primary + % Savings

Only (Kwh) CS (Kwh)
CHW
Pumping
Energy 97,052 63,430 34.64%
Consumption
Distributed Pumping System – Few references
Distributed Pumping System – Few references

Kostal Project, Ranipet

HVAC Consultants – M/s Enersave Solutions
Chennai

Air-conditioned Area: 47,218 [Link]

5 units of AHU
1 Chillers - 200 TR
Climaveneta FX/CA/3902
2 units of 7.5 kW Variable Primary Pump
5 units of Coil Pumps
Distributed Pumping System – Few more references

Primary Primary + % Savings

Only (Kwh) CS (Kwh)
CHW
Pumping
Energy 56,368 45,749 19.22%
Consumption
Distributed Pumping System
Distributed Pumping ADVANTAGES
• Hydraulically Self-Balanced
• No balancing valves required

• No modulating valves required

• Less flow resistance in the piping network
• Savings in Pumping Energy

• No DP sensors and DP setpoint required

Coil Pump
• Control strategy for variable Primary Pump speed based on
chilled water supply meeting exactly with Load required

• Comparable capital cost

• Primary-Only System:
• Balancing valves + Modulating valves + Larger primary pumps
• Primary-Coil Secondary (P-CS) System:
• Coil pumps + check valves + smaller primary pumps

Decoupler • Simpler commissioning process

• Shorter commissioning period
Chiller • Man power savings in commissioning

Chiller • Energy savings in Chillers & Plant

Primary Pump • No excessive amount of chilled water to be cooled
Primary-Coil Secondary (P-CS)
Thank you
for your
valuable
time