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number of pumps to operate at each system
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gal/min
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Basics of Pump Application for HVAC Systems 304 The HVAC World
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TABLE 1010
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Total kW Input Calculations for a 100 Percent Constant-Speed Pump System head, ft 309 332 367 414 472 541 620 710 810 920 Water hp 23 50 83 125 179 246 329 430 552 697 Fitting loss, ft 01 03 07 13 20 29 39 51 65 80 Pump head, ft 138 137 136 133 129 126 122 117 110 100 Pump rpm 1780 1780 1780 1780 1780 1780 1780 1780 1780 1780 Pump effy 20 37 50 60 68 74 80 84 88 90 Motor effy 960 960 962 962 962 961 961 961 961 961 Input kW 406 436 479 521 558 601 628 655 661 654
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System gal/min 300 600 900 1200 1500 1800 2100 2400 2700 3000
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3 The constant-speed, 100 percent capacity pump is very inefficient excepting at full load This is due to the elimination of the inefficiency of the variable speed drive 100 percent speed 4 A combination of two 50 percent pumps and one 100 percent pump would offer the optimum efficiency
Conclusions The installed pump horsepower is 200 hp for the two 100
percent pumps, 150 hp for the three 50 percent pumps, and 200 hp for a system consisting of two 50 percent pumps and one 100 percent pump Before a final selection of pump capacity is made, a thorough evaluation must be made of the actual load curve for the water system If most of the loads are 1500 gal/min or less with peak loads occurring momentarily, there probably is no justification for the use of a 100 percent capacity pump If the daily load is above 2000 gal/min with light loads occurring during the night hours, the combination of two 50 percent pumps and one 100 percent pump may be the best selection Other factors that must apply are, of course, first cost, cost of power, and all other pertinent information that must be reviewed in each case of pump application This study reveals that the proper selection of pumps, both in size and number requires a sizeable amount of information and calculations to determine the most feasible pumping equipment for a particular installation It should be noted that the above tables are based upon standard water at 60 F If kW inputs are computed for liquids of other densities or viscosities, the head inserted in the tables should be corrected for the actual density and viscosity This evaluation was made on a specific installation without any preconceived results The important factor about this analysis is the method used, not the results that are specific for this water system
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Basics of Pump Application for HVAC Systems Basics of Pump Application for HVAC Systems 305
70 One pump, 100% capacity, constant speed 60
50 Two pumps, 50% capacity, variable speed 40
kW Input
One pump 50% capacity, variable speed
One pump 100% capacity, variable speed
1500 System flow GPM
kW input for Tables 108, 109, and 1010
10101 Total kW input indication and pump programming
Total kW input indication for an actual pumping system can be displayed easily on the pumping system controller The operator can observe the kW input before a pump is added or subtracted kW input is an excellent procedure for programming variable-speed pumps in a multiple-pump installation Rather than waiting for a system
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Basics of Pump Application for HVAC Systems 306 The HVAC World
condition to start or stop pumps, the kW input control starts or stops a pump when these actions indicate a possibility of saving energy For example, in Table 109 and Fig 1016, the data indicates that the second pump should be started when the system flow reaches 1300 gal/min and not wait until 1800 gal/min flow where one pump can no longer sustain the desired water system conditions At 1800 gal/min, the kW input with one pump running is 335 kW and is 263 kW with two pumps running This is a 21 percent savings in energy The software of the pump controller can include this control procedure to ensure that the most efficient number of pumps is running in a multiple-pump installation The points of addition and subtraction for pumps are easily adjustable in contemporary pump controllers One of the advantages of this control is the ability of the operators to check the control procedure to ensure that the pump addition and subtraction points are correct This is as follows and assumes that the desired operating pressure is maintained as pumps are added and subtracted 1 The total kW input should drop when a pump is added If it increases instead, the pump should not have been added, and the set point for pump addition should be increased until the kW input drops or does not change when a pump is added 2 The total kW input should drop when a pump is subtracted Like the pump addition, if the kW input increases when a pump is subtracted, the point of subtraction should be lowered until the kW input drops or does not change when subtracting a pump This is a very simple procedure even for installations with a multiple of large pumps The operators become familiar with what the kW input should be at particular flows in the water system and can tell when adverse conditions appear 1011 Pump Control Since variable-speed pumps have entered the HVAC market, there are two aspects to pump control: (1) pump start-stop procedures and (2) pump speed control These procedures must be developed for both constant- and variable-speed pumping systems Pump start-stop procedures consist of a number of control techniques: 1 With system activation or shutdown 2 By system demands such as flow or pressure 3 By system energy evaluation such as wire-to-water efficiency or kW input
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