Booster Pump Fundamentals. By: Bill Baglot
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1 Booster Pump Fundamentals By: Bill Baglot March 22,
2 Booster Pumps
3 Presentation Topics What are Booster Pumps and when do we need them Accurately sizing boosters and drawdown tanks Maximizing Energy Efficiency while reducing sound levels and required starting torque Maximizing Energy Conservation while reducing footprint and drawdown tank sizing
4 Key Terms
5 Booster Pumps A booster pump is a pump that increases fluid pressure while maintaining a specified flow rate When do we need a booster pump? When the water pressure supplied by the municipality cannot reach the highest fixture on the building with a typical residual pressure of at least 30 psig May need one set for hot and one for cold
6 Pump A device that increases pressure while maintaining a desired flow rate. Motor (TEFC) Pump volute Mechanical Sealand Bearing Impeller March 22,
7 Expansion Tank A tank with water on one side of a barrier (Typically a rubber bladder or diaphragm) and fluid on the other. The air pressure is set to the desired system pressure and can expand or contract depending on the fluid pressure on the other side of the barrier.
8 Drawdown Tank Expansion tank designed to have a large acceptance volume that can be used to push water back into a system when the booster pumps shut down Acceptance Volume Amount of usable water that can be drawn from an expansion tank while maintaining a set system pressure
9 Fixture Units (FU) A measure of the rate at which various plumbing fixtures discharge into a drainage system, stated in units of cubic volume per minute. ASPE Tables Equal to one cubic foot of water drained in an 1 1/4 pipe over one minute. One cubic foot of water is roughly 7.48 gallons ( 6.25 Imperial Gallons). Fixture Units are used in plumbing design for both water supply and waste water.
10 Motor Technology Permanent Split Capacitor Motor (PSC) Standard for many years stator is the stationary part of a rotary system rotor is the rotating electrical component. Stator Rotor
11 Wet Rotor Technology
12 ECM Electronic Commutated Motor Permanently magnetized rotor Multiple poles around stator Pulse DC energy to each pole and attract magnet Can send pulses at speed of Electricity Reality is that we can send pules to rotate as high as 7000
13 EC Motor Technology 1. High starting torque up to 3 times a standard motor 2. Inherent variable speed still need a sensor 3. Energy savings due to permanent magnet rotor 4. High RPM with compact pumps
14 Variable Frequency Drive (VFD) A Variable Frequency Drive (VFD) is a type of motor controller that drives an electric motor by varying the frequency and voltage supplied to the electric motor. Changing the frequency increases or decreases the RPM s of the motor
15 Information Required to Size Booster Pumps Calculate how much water we need to supply What pressure we need to supply the water at Power considerations Sound / Noise considerations What accessories we need (Drawdown tank, VFD s, or ECM) Layout of the package (Footprint and location) Efficiency requirements
16 Calculating Required Flow Several systems available to allocate fixture units for each fixture Calculate the fixture units for each area on the system and then total them Convert the fixture units to GPM Several Tables available, but the best information we have although becoming outdated is the Hunter curves These have been modified to try and reflect the changing makeup of residents in towers The most widely accepted tables available are from the ASHRAE Handbook HVAC
17 Revised Hunter Curves ASHRAE HVAC
18 Typical chart from 10 years ago, still out there
19 Calculating Head on Boosters There are 4 head losses that need to be considered to determine system head HS Static head (Elevation or vertical lift (Typical ft/floor)
20 HF Friction Head (Losses from piping and fittings) HF = {HV + HLHR + HFT} x (PD/F) HV = Longest vertical pipe rise in feet HLHR = Longest horizontal pipe run HFT = Fitting Allowance PD/F = Pressure drop per hundred foot of pipe (From tables)
21 HR Residual Head Pressure (Delivery pressure required at furthest fixture) HI Inlet Head Pressure. Minimum supply pressure guaranteed by the municipality
22 Calculating booster pump head HS + HF + HR HI = TPR Total Pressure Required (Dynamic Head) Example a 30 story residential High-rise Use 5 ft/100ft for friction loss, LHR =80 ft, 2200 fixture units HS = 31 floors (P1-30 th floor) x 10 feet/floor = 310 ft HF = {HV + HLHR + HFT} x 5ft/100ft = [ (390 x 5%)] x.05 = 20.5 ft HR = 30 psi = 69.3 ft HI = 30 psi promised **** = 69.3ft TPR = , = ft Flow from ASHRAE chart = 140 GPM at 2200 FU
23 Our Booster is Oversized These calculations give us what should be the peak demand on the system. We have to consider today s diversity The system will only be at peak loads 20-25% of the time.
24 Other information required to size a booster pump system 1. Sound levels (Especially during the evening and quiet times) 2. Electrical Considerations 3. Starting Torque high torque can lead to higher peak demands and higher electricity costs 4. Large footprints floor space is typically a premium 5. Accurately sizing drawdown tanks Make the tanks as small as practically possible to reduce cost and floor space 6. Placement of drawdown tank - avoid ASME when practical
25 Sound Levels Historically booster pumps have been limited to 1800 RPMs Todays reality is that we have variable speed drives or ECM motor technology that allow us to use pumps capable of from 800 to 5400 RPMs
26 The pumps come on slowly (800 RPM) and slowly ramp up full speed. Minimum starting speed is 30% of total flow for pumps that have seals and VFD / ECM motors (ECM available to 10HP) 12% for pumps that have a wet rotor and ECM motor technology (Only to 3HP) Sound issues disappear in wet rotor due to the water jacket in the motor acting as a sound barrier
27 STARTING TORQUE High starting torque causes high peak usage of power many buildings are charged power rates associated with their peak usage By starting pumps with split capacitor motors at their minimum (30%) and ramping the speed up you avoid peak usage charges Using an ECM motor completely avoids high peak charges when starting the pumps
28 Drawdown Tanks Traditional systems the pumps were either on or off, so as long as there was demand the pumps ran. Even one fixture open caused the pumps to run. The pump motors required minutes to cool between cycles. Led to pump failures. At night the noise of a pump starting could be heard throughout the building
29 Drawdown tank was introduced to hold enough water at pressure to keep the system supplied, so the pumps could cool down between cycles, eliminate short cycling of the pumps and reduce noise from starts late at night
30 The tanks were typically huge, expensive, and required a great deal of floor space. If installed at the bottom of the building the tank had to be ASME in order to handle the high pressures. If installed on the roof we had lower pressure required, but do to the high volume requirements the tanks were over 24Ø still needed to be ASME.
31 Along came the VFD Now pumps would start and stop at their minimum so they needed less time to cool lead / lag controls built-in to the pump controllers you could start the next pump and give the first pump more time to cool
32 Pumps started at lower flows and made less noise Drawdown tanks could now be sized smaller than before, of course the DD tanks were not
33 Along came ECM booster pumps Pump motors ran cooler and needed a much shorter wait between cycles than a VFD controlled motor Sound dampening design of the motor almost eliminated sound as an issue. Pumps came on as low as 10% of the system flow in a 33%-33%-33% triplex
34 Why use the ECM over VFD Since the faster you spin the impeller the more water you move, an ECM pump can be half the size and achieve the same flow and head as a conventional pump typically up to 5400 RPM
35 What does all this Mean Drawdown tank only needs to be large enough to give controls time to shift to next pump and to handle the possible water hammer if the last fixture is closed and the water hammer arrestors on the system fail
36 How do we Maximize Energy Conservation? Use ECM technology (Available up to 10 HP) Switch pumps intelligently to make sure we have the minimum HP being used at all times Use smaller pumps whenever possible Choose our pumps to allow us the greatest range possible (33%-33%-33%)
37 Use smaller pumps with less than 100% redundancy Use three pumps 50%-50%-50% for 50% redundancy and a minimum flow rate of 15% of system flow for standard motors or for ECM motors Alternatively we could use 33%-33%-33%-33% for a 33% redundancy with a minimum system flow of 10% for standard motors or ECM motors
38 We can use different size pumps in the package and /or use 4 pumps % or % Run the smallest pump at 30% of its capacity (6% of the total flow)
39 Footprint Considerations We can build as normal with rectangular base with panel on one end
40 Ship pumps as one piece and the panel separate.
41 We can use vertical pumps with stacked impellers and pump mounted VFD s or ECM technology so we can put all the pumps in a small line and mount the panel on the wall Retrofit Market We can design the footprint to get the equipment through the doors, and also to fit in the existing footprint
42 Footprint Considerations Design the drawdown tank to be mounted on the package For larger drawdown tanks we can make them taller and slimmer (Less than 24 Ø and mount them at the top of the system, avoid ASME if possible.
43 Starting Booster Pumps - Reality Typically the building has low occupancy in the beginning The boosters are designed to provide water for Phase 1 and 2, Phase 2 will not be on line for 2 years. The municipality is providing 70 psi instead of 30 psi
44 Possible Solutions Oversize the DD tank Change the pump configurations to match what is going to happen Example Design with
45 Selection Information Required Once we have our head and flow calculated we need to decide how much diversity to allow for. How many booster pumps required with what redundancy and what percentage of the total flow we want on each pump Decide on the location and size of the drawdown tank Look at where we can put the package and drawdown tank Select the pumps and controls
46
47 AVOID AT ALL COSTS - HUGE LIABILITY ISSUE
48 Booster Configurations in Buildings Standard Boost cold water to roof and make hot water at roof Have separate Boosters for hot and cold water reduces space required at the top of the building, smaller DCW main. Recommended for District Energy applications District Energy alternate We do not recommend. Requires large booster pumps with very high pressure drops
49 Extra Tall Buildings 40 Stories and over We recommend a secondary booster part way up the building. Lower pressure and avoids welded pipe and removes the requirement for high pressure rating on the system components
50 Questions
51 WHAT IF I DON T REMEMBER? Call E138 Or Or bill.baglot@olympicinternational.com March 22,
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