domestic water booster system sizing & specification
TRANSCRIPT
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DomesticWaterBoosterSystemSizingandSpecifying
TS10012
Friday2:45pm5:45pm
RichardHanson
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My Project Goals99Did the design meet the technical and
commercial needs?
9Was the product the best value for the budget?9 If something broke did the pumps still run?9 If something broke, did the pumps still run? 9Does it still run automatically years after y y
shipment?
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Operator Needs
Operator/Svc Tech High price for failure
Development Goal Minimize Shutdowns g p
Eliminate Complaints Conserve Energy
Lower TCO Minimize Adjustments Multiple Price Points
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I take your project as seriously as you do
Operator confidence Total cost ofTotal cost of
ownership over time Singlesource Singlesource
responsibilityNationwide network Nationwide network
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Domestic Water Boosters9Whats New9Notes to SelfNotes to Self
9Sizing Recommendations
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Top New TechnologiesTop New Technologies
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Third Party CertificationsThird-Party Certifications
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Troubleshooting and Mods9Download pump
system info to transmit 9Upload program
changes
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Networked C tiConnection
9Read All VFD data9Read All VFD data 9 300 VFD parameters
through the PLCthrough the PLC9BACNet Conn Still
AvailableAvailable
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VFD Energy Savings Mode9Sl d th t9Slows down the motor9 reduces current9R d lt9Reduces voltage9Evaluates 6 motor
h t i ti t f thcharacteristics to further increase efficiency9 3 HP Example: 41 > 269 3 HP Example: .41 -> .26
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VFD Protection
VFD's up to 40 HP inside a NEMA 1inside a NEMA 1 enclosureFan cooled with Fan-cooled with positive pressureThermostat Thermostat-controlled
NEMA 12 Option NEMA 12 Option
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VFD Benefits ENERGY SAVINGS Smooth hydraulicsSmooth hydraulics Pressure adjustment
Maintenance of PRVs Maintenance of PRV s When recommended?
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Demand(GPM) % Ti
AnnualH
CurrentS i
CurrentP HP
AnnualkW
FutureS i
FutureP HP
FuturekW
kWS i
Real Example(GPM) %Time Hours Sequencing PumpHP kW Sequencing PumpHP kW Savings
50% 4,380 Pump1 6.0 23,055 Off 0 23,055
1 5% 438 Pump1 6.0 2,306 Pump1 3 1,153 1,153
40 10% 876 Pump1 10.0 7,685 Pump1 5 3,843 3,843
80 10% 876 Pump1 13.0 9,991 Pump1 8 6,148 3,843
120 10% 876 1 & 2 23 5 18 060 Pump 1 10 7 685 10 375120 10% 876 1&2 23.5 18,060 Pump1 10 7,685 10,375
140 8% 700 1&2 24.2 14,878 Pump1 10 6,148 8,730
160 3% 262 1&2 24.6 5,672 Pump1 13.5 3,112 2,559
200 1% 87 1&2 25.0 1,921 Pump2 15 1,153 769
220 1% 87 1&2 27.8 2,136 Pump2 16.5 1,268 868
240 1% 87 1 & 2 30 7 2 359 P mp 2 18 1 383 976240 1% 87 1&2 30.7 2,359 Pump2 18 1,383 976
280 1% 87 1&2 36.6 2,813 Pump2 27 2,075 738
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Estimated Savings20,000
25,000
15,000
0,000
10,000
5,000
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Future KW Savings
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Energy Savings Tank Tank LocationTank Location Pump Duty Point
Pump Speed Pump Speed Pump Type VFD
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Tank Location
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Additional benefits: Easy start-ups More reliable and self-sufficient operation Increased motor bearing and seal life Increased motor bearing and seal life Dramatically reduced sound and motor heat More information is available to the operatorMore information is available to the operator
alarm logs data history
adjustable keypad settings adjustable keypad settings Remote access to data
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Panel SCCR Rating 65 kA9The VFD is *NOT* the weakest link in the
power circuit; it has a 100,000 amp short-circuit current rating. 9A power surge is more likely going to fryA power surge is more likely going to fry
the disconnect than the VFD.
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Certified Touchsafe9IP109IP109IP20
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Pressure Transmitter9Not the place to save money!
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New Sequencing Possibilities Pressure Flow VFD Speed Power Combinations thereof Repressurization Mode
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Problem Flow sequencing is best way to prevent
pump cycling BUT . . . Flow switches: inaccurate, unreliable Flow sensors: unreliable, expensive, p Installation is expensive, unreliable
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Low Flow Verification ProblemFl it h (1 FPS) $ Flow switch (1 FPS) $
Paddlewheel flow sensor (1/4 FPS) $$ Magnetic flow sensor (1/8 FPS) $$$$$
1/4 FPS in a 4 pipe = 10 gpm1/4 FPS i 6 i 20 1/4 FPS in a 6 pipe = 20 gpm
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Solution PLAN - sense low flow (power,
pump differential, VFD speed)O DO - slow down pump
CHECK to see if pressure holds (3 psi)holds (3 psi)
ACT - stop pump if pressure holdsholds
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Added Charge Just before shutdown 10 psi standardp Adjustable
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Solution Pressure PowerPower Differential
Pressure Pressure VFD Speed
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Power vs. Pressure
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New Pumps to Consider
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Low Flow Energy SavingsEnergy Savings
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Problem: D tDust
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Solution:
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Other Added ValueValue
Lonworks or BACN tBACNet Communication
3D CAD drawings/BIM integration
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Sizing Basics
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Do You Need a Booster?Do You Need a Booster?
Building Height (ft x .433 -> PSI) + Friction Losses+ Friction Losses + Pressure Required at Top = Pressure Required atPressure Required at
Base of Building
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+ Friction Losses (10% approximately) Bernoullis EquationBernoulli s Equation
Most common error today?? Most common error today??
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Pressure Required @ TopPressure Required @ Top
Flush ValvesC li T Cooling Tower
High-End Showers
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Do You Need a Booster?Do You Need a Booster?
B ilding Height (ft 433Building Height (ft x .433 = PSI)
+ Friction Losses + Pressure Required at Top = Pressure Required at
Base of Building
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Example: 10 Story Hotel
Building Elevation (10 floors 12/floor) 10 fl 12/fl 120
52 psi +
10 floors x 12/floor = 120120 x .433 psi/ft
Friction losses 5 psi +Friction losses (52 psi x .1)
5 psi +
Pressure Required at top 30 +q pNo cooling tower, 30 psi for FV
Pressure Required at Base ( k S t P )
= 87 psig(aka System Pressure)
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Boost Pressure Calc.
Pressure Required at Base of Building(aka System Pressure PSIG)(aka System Pressure - PSIG)
- Pressure @ flow test location+/- Elevation change- Water Meter loss- Water Softener loss= Pump System Boost (PSID)= Pump System Boost (PSID)
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Example: 10 Story HotelExample: 10 Story Hotel
System (discharge) Pressure 87 psig
Minimum Suction (incoming) Pressure 30 psigPressure 30 psig
Pump System DifferentialPump System Differential87 psig 30 psig = 57 psid
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Scheduling Your BoosterPump System Boost (we recommend)
+ 5 PSI Internal Losses 5 PSI Internal Lossesx 2.31 = Pump TDH (commonly specd)
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Protect Yourself!
This System Pressure
Not This Pump TDH System Pressure
Minimum Suction
Pump TDH
Maximum Suction
120 PSI Discharge50 PSI Min S ction
162?173?50 PSI Min. Suction
70 PSI Maximum
173 ?
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Pressure Control Bottom Zone Zone PRVsZone PRV s
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Estimating FlowEstimating Flow
Codes Practice
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Hunters vs Actual
Oversized By:Occupancy Type
30-75%?Apartment, Office, School
25-55%?Hotels, Motels
Just Right!Stadiums
10-40%?Hospital, Schools
Just Right!Stadiums
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Redundancy Recommendations
Redundant PumpsOccupancy Type
0Apartment, Office, School, Hotel
1Hospital, Stadiums
,
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Example: Yankee Stadium 369 Womens Toilets 98 Mens Toilets 298 Mens Urinals 150 Lavatories 150 Lavatories 50 Kitchens
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369 Womens Toilets98 Mens Toilets298 Mens Urinals150 Lavatories50 Kitchens
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E ti ti FlEstimating Flow
Fixture Type Count FU Total
T il tToilets
Urinals467 10 4670
298 5 1490Urinals
Lavatories
298 5 1490
150 2 300
Kitchens 50 4 200
6660 fixture units -> 900 gpm approximately
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Example: Embassy Suites 20 Story Hotel 50 Rooms/Floor50 Rooms/Floor Lower 3 Floors on City Pressure
Flush Tank Toilets in Rooms Flush Tank Toilets in Rooms
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20 Story Hotel y 50 Rooms/Floor Lower 3 floors on city
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Estimating FlowEstimating Flow
Fixture Type Count FU Total
BathroomGroup
S
850 3.6 3060
Bar Sink
Mop Sink850 1.4 1190
68 3 204Mop Sink
Icemaker
68 3 204
68 25? 1768 .25? 17
4471 fixture units -> 580 gpm
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Pump OptionsPump Options
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Discussion Points Importance of selecting the right pump Typical pumps used in plumbingTypical pumps used in plumbing Best application for each type
Reading a pump curve Reading a pump curve Matching a pump with a system curve Optimal solution
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Importance of the Right Pump Selecting the right pump for the application Selecting the highest efficiency pumpSelecting the highest efficiency pump Selecting a good quality pump
Understanding the cost of down time Understanding the cost of down time
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Most Popular PumpsMost Popular Pumps
Close-coupled Flex-coupled End pEnd Suction
Vertical Turbine
pSuction
Vertical MultistageVertical Turbine Column-mounted
Turbines
Vertical Multistage Horizontal Split
CaseTurbines Case Self-priming
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End SuctionEnd Suction Most popular pump in the world Most popular pump in the world Small compact design For low flows @ low-medium head Lowest initial cost Easy to maintain
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End Suction Pump Curve
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Horizontal Split Casep
Larger foot print Best for high flows
and high heads Best design pump
resulting in many years of trouble free
i ifservice if . . . Used in variety of
li ti i l diapplications including fire fighting
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HSC Pump Curve
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Vertical MultistageVertical Multistage
Low flows at high heads Minimal space
requirements Low first cost High shutoff pressureg s uto p essu e
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VMS Pump Curve
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Vertical Turbine Pump
Low - high flows @high - very high headshigh very high heads
Minimal footprintW ll b t i t ll ti Well or booster installation
Very high quality, but . . . High efficiencies
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VT Pump Curve
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Self PrimingSelf-Priming
Mainly used yfor lifting waste water
Solids handlinghandling capabilityAi t l? Air control?
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MATCHING PUMP WITH SYSTEM CURVE
PPump curve
HEADSystem Curvesy
FLOW
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Proper Pump Selection
Determine selection criteriaM f t th t t Manufacturer that supports you
Meets technical requirements Highest possible efficiency Select pump size closest to bestSelect pump size closest to best
efficiency point Confirm space availability Confirm space availability
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General Recommendations
Boost Pressure
Total System Flow 50 psi
0 400 gpm boost 2 ES 2 VMS*0 400 gpm boost 2 ES 2 VMS
400 900 gpm 3 ES 3 VMS*
>900 b t 3 HSC 3 VT>900 gpm booster 3 HSC 3 VT
* If VFD* If VFD
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Pressure Control OptionsPressure Control Options
Variable Speed PumpP R l ti Pressure Regulating Valve
Zone PRVs 3-5 floors None Requiredq
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Tank SizingTank Sizing
Higher in the building is better if no PRVs How big a tank?How big a tank?
Acceptable leak load? Minimum pump flow?Minimum pump flow? Additional installation cost for bigger tank?
Maintenance replacement of bigger tanks? Maintenance, replacement of bigger tanks?
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Tank Efficiency
Bigger the better forEnergy savings Energy savings
Reducing pump cycling Smaller the better for
Cost Installation
Maintenance Maintenance
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RecommendationsRecommendations
100 Gallon minimum36 80 i 36 x 80 maximum
Top of building if any of these Top of building if any of these VFD No PRVNo PRV >200 psi Steady suction pressure
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ASPE Recommendation
Leak load 0.5% for most commercial buildingsg 4% for Hospitals
Size for 10-30 minute off time
Locate based on largest storage opportunity using Boyles Lawopportunity, using Boyle s Law.
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Conclusion Find a partner that you trust to provide a
design that meets your needsOR
Confirm that some product can meet your Confirm that some product can meet your WHOLE specification and drawing
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Online Sizing GuideOnline Sizing Guide
http://www.syncroflo.com/boostersizing/step1.phpg
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Online Resources http://www.pumpsystemsmatter.org/ http://www.pmengineer.com/Articles/Coverhttp://www.pmengineer.com/Articles/Cover
_Story/BNP_GUID_9-5-2006 A 100000000000003271452006_A_10000000000000327145
TS 100-1-2Hanson_Richard