DomesticWaterBoosterSystemSizingandSpecifying

TS10012
Friday2:45pm5:45pm
RichardHanson

My Project Goals
9 Did the design meet the technical and
commercial needs?
9 Was the product the best value for the budget?
9 If something broke,
broke did the pumps still run?
9 Does it still run automaticallyy yyears after
shipment?

Operator Needs
Operator/Svc Tech
High
g p
price for failure
Eliminate Complaints
Conserve Energy

Development Goal
Minimize Shutdowns
Lower TCO
Minimize Adjustments
Multiple Price Points

I take your project as seriously as you do

Operator confidence
Total cost of
ownership over time
Singlesource
responsibility
Nationwide network

Domestic Water Boosters

9Whats New
9Notes
Notes to Self
Self
9Sizing Recommendations

Top New Technologies

Third Party Certifications

Third-Party

Troubleshooting and Mods

9 Download pump
system info to transmit
9 Upload program
changes

Networked
C
Connection
ti
9 Read All VFD data
9 300 VFD parameters
through the PLC
9 BACNet Conn Still
Available

VFD Energy Savings Mode

9 Slows
Sl
d
down th
the motor
t
9 reduces current
9 Reduces
R d
voltage
lt
9 Evaluates 6 motor
characteristics
h
t i ti tto ffurther
th
increase efficiency
9 3 HP Example: .41
41 ->
> .26
26

VFD Protection

VFD's up to 40 HP
inside a NEMA 1
enclosure
Fan-cooled
Fan cooled with
positive pressure
ThermostatThermostat
controlled
NEMA 12 Option

VFD Benefits

ENERGY SAVINGS
Smooth hydraulics
Pressure adjustment
Maintenance of PRVs
PRV s
When recommended?

Demand
(GPM)
(GPM)

% Ti
%Time

Annual
H
Hours

50%

4,380

5%

40

Current
S
Sequencing
i

Current
P
PumpHP
HP

Annual
kW

Future
S
Sequencing
i

Real Example

Future
P
PumpHP
HP

Future
kW

kW
S i
Savings

Pump1

6.0

23,055

Off

23,055

438

Pump1

6.0

2,306

Pump1

1,153

1,153

10%

876

Pump1

10.0

7,685

Pump1

3,843

3,843

80

10%

876

Pump1

13.0

9,991

Pump1

6,148

3,843

120
120

10%

876

1&2
1&2

23 5
23.5

18 060
18,060

Pump 1
Pump1

10

7 685 10,375
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
240

1%

87
87

1&2
1&2

30 7
30.7

2 359
2,359

P mp 2
Pump2

18

1 383
1,383

976
976

280

1%

87

1&2

36.6

2,813

Pump2

27

2,075

738

25,000

Estimated Savings

20,000
0,000

15,000

10,000

5,000

Future KW

Savings

Energy Savings

Tank
Tank Location
Pump Duty Point
Pump Speed
Pump Type
VFD

Tank Location

Additional benefits:

Easy start-ups
More reliable and self-sufficient operation
Increased motor bearing and seal life
Dramatically reduced sound and motor heat
More information is available to the operator

alarm logs
data history
adjustable keypad settings
Remote access to data

Panel SCCR Rating 65 kA

9The VFD is *NOT* the weakest link in the
power circuit; it has a 100,000 amp shortcircuit current rating.
9A
A power surge is more likely going to fry
the disconnect than the VFD.

Certified Touchsafe
9IP10
9IP20

Pressure Transmitter
9Not the place to save money!

New Sequencing Possibilities

Pressure
Flow
VFD Speed
Power
Combinations thereof
Repressurization Mode

Problem
Flow sequencing is best way to prevent
pump cycling BUT . . .
Flow switches: inaccurate, unreliable
Flow sensors: unreliable,, expensive
p
Installation is expensive, unreliable

Low Flow Verification Problem

Flow
Fl
switch
it h (1 FPS) $
Paddlewheel flow sensor (1/4 FPS) $$
Magnetic flow sensor (1/8 FPS) $$$$$
1/4 FPS in a 4 pipe = 10 gpm
1/4 FPS iin a 6 pipe
i = 20 gpm

Solution
PLAN - sense low flow (power,
pump differential, VFD speed)
DO
O - slow down pump
CHECK to see if pressure
holds (3 psi)
ACT - stop pump if pressure
holds

Added Charge
Just before shutdown
10 p
psi standard
Adjustable

Solution

Pressure
Power
Differential
Pressure
VFD Speed

Power vs. Pressure

New Pumps to Consider

Low Flow
Energy Savings

Problem:
D t
Dust

Solution:

Other Added
Value
Lonworks or
BACN t
BACNet
Communication
3D CAD
drawings/BIM
integration

Sizing Basics

Do You Need a Booster?

Building Height (ft x .433 -> PSI)

+ Friction Losses
+
Pressure Required at Top
= Pressure Required at
Base of Building

+ Friction Losses
(10% approximately)
Bernoulli
Bernoullis
s Equation
Most common error today??

Pressure Required @ Top

Flush Valves
Cooling
C li T
Tower
High-End Showers

Do You Need a Booster?

Building
B
ilding Height (ft x .433
433 =
PSI)
+ Friction Losses
+ Pressure Required at Top
= Pressure Required at
Base of Building

Example: 10 Story Hotel

Building Elevation

52 psi +

(10 floors 12/floor)

10 flfloors x 12/fl
12/floor = 120
120 x .433 psi/ft

Friction losses

5 psi +

(52 psi x .1)

Pressure Required
q
at top
p

30 +

No cooling tower, 30 psi for FV

Pressure Required at Base

( k S
(aka
System
t
Pressure)
P
)

= 87 psig

Boost Pressure Calc.

Pressure Required at Base of Building
(aka System Pressure - PSIG)
- Pressure @ flow test location
+/- Elevation change
- Water Meter loss
Water Softener loss
= Pump System Boost (PSID)

Example: 10 Story Hotel

System (discharge)
Pressure 87 psig
Minimum Suction (incoming)
Pressure 30 psig
Pump System Differential
87 psig 30 psig = 57 psid

Scheduling Your Booster

Pump System Boost (we recommend)
+
5 PSI Internal Losses
x 2.31 = Pump TDH (commonly specd)

Protect Yourself!

This
System Pressure
Minimum Suction
Maximum Suction

Not This
Pump TDH

120 PSI Discharge

50 PSI Min
Min. S
Suction
ction
70 PSI Maximum

162?
173?
173
?

Pressure Control
Bottom Zone
Zone PRVs
PRV s

Estimating Flow
Codes
Practice

Hunters vs Actual

Occupancy Type

Oversized By:

Apartment, Office, School

30-75%?

Hotels, Motels

25-55%?

Hospital, Schools

10-40%?

Stadiums

Just Right!

Redundancy Recommendations
Occupancy Type

Redundant Pumps

Apartment, Office,
School,, Hotel

Hospital, Stadiums

Example: Yankee Stadium

369 Womens Toilets

98 Mens Toilets
298 Mens Urinals
150 Lavatories
50 Kitchens

369 Womens Toilets

98 Mens Toilets
298 Mens Urinals
150 Lavatories
50 Kitchens

E ti ti Flow
Estimating
Fl
Fixture Type

Count

FU

T il t
Toilets

467

10

4670

Urinals

298

1490

Lavatories
Kitchens

Total

150

300

50

200

6660 fixture units -> 900 gpm approximately

Example: Embassy Suites

20 Story Hotel
50 Rooms/Floor
Lower 3 Floors on City Pressure
Flush Tank Toilets in Rooms

 20 Story
y Hotel
50 Rooms/Floor
Lower 3 floors on city

Estimating Flow
Fixture Type
Bathroom
Group
Bar Sink
S

Count

FU

Total

850

3.6

3060

850

1.4

1190

Mop Sink

68

204

Icemaker

68

.25?
25?

17

4471 fixture units -> 580 gpm

Pump Options

Discussion Points

Importance of selecting the right pump

Typical pumps used in plumbing
Best application for each type
Reading a pump curve
Matching a pump with a system curve
Optimal solution

Importance of the Right Pump

Selecting the right pump for the application

Selecting the highest efficiency pump
Selecting a good quality pump
Understanding the cost of down time

Most Popular Pumps

Close-coupled
p
End Suction
Vertical Turbine
Column-mounted
Turbines

Flex-coupled
p
End
Suction
Vertical Multistage
Horizontal Split
Case
Self-priming

End Suction

Most popular pump in the world

Small compact design
For low flows @ low-medium head
Lowest initial cost
Easy to maintain

End Suction Pump Curve

Horizontal Split
p Case
Larger foot print
Best for high flows
and high heads
Best design pump
resulting in many
years of trouble free
service
i if . . .
Used in variety of
applications
li ti
iincluding
l di
fire fighting

HSC Pump Curve

Vertical Multistage

Low flows at high heads

Minimal space
requirements
Low first cost
High
g sshutoff
uto pressure
p essu e

VMS Pump Curve

Vertical Turbine Pump

Low - high flows @

high - very high heads
Minimal footprint
W ll or b
Well
booster
t iinstallation
t ll ti
Very high quality, but . . .
High efficiencies

VT Pump Curve

Self Priming
Self-Priming

Mainlyy used
for lifting
waste water
Solids
handling
capability
Air
Ai control?
t l?

MATCHING PUMP WITH SYSTEM CURVE

Pump
curve
HEAD
System
y
Curves

FLOW

Proper Pump Selection

Determine selection criteria

M
Manufacturer
f t
that
th t supports
t you
Meets technical requirements
Highest possible efficiency
Select pump size closest to best
efficiency point
Confirm space availability

General Recommendations

Boost Pressure
Total System Flow

<50 psi

> 50 psi

0 400 gpm boost

2 ES

2 VMS
VMS*

400 900 gpm

3 ES

3 VMS*

3 HSC

3 VT

>900 gpm b
booster
t

* If VFD

Pressure Control Options

Variable Speed Pump

Pressure
P
R
Regulating
l ti
Valve
Zone PRVs 3-5 floors
q
None Required

Tank Sizing

Higher in the building is better if no PRVs

How big a tank?
Acceptable leak load?
Minimum pump flow?
Additional installation cost for bigger tank?
Maintenance,
Maintenance replacement of bigger tanks?

Tank Efficiency

Bigger the better for

Energy savings
Reducing pump cycling
Smaller the better for
Cost
Installation
Maintenance

Recommendations
100 Gallon minimum
36 x 80 maximum
i
Top of building if any of these
VFD
No PRV
>200 psi
Steady suction pressure

ASPE Recommendation
Leak load
0.5% for most commercial buildings
g
4% for Hospitals

Size for 10-30 minute off time

Locate based on largest storage
opportunity using Boyles
opportunity,
Boyle s Law.
Law

Conclusion
Find a partner that you trust to provide a
design that meets your needs
OR
Confirm that some product can meet your
WHOLE specification and drawing

Online Sizing Guide

http://www.syncroflo.com/booste
rsizing/step1.php
g

Online Resources
http://www.pumpsystemsmatter.org/
http://www.pmengineer.com/Articles/Cover
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2006_A_10000000000000327145