Domestic Water Booster System Sizing and Specifying 
TS 100‐1‐2 
Friday 2:45pm‐5:45pm 
Richard Hanson 
 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 Development Goal
• High
g pprice for failure • Minimize Shutdowns
• Eliminate Complaints • Lower TCO
• Conserve Energy • Minimize Adjustments
• Multiple Price Points
I take your project as seriously as you do

• Operator confidence
• Total cost of
ownership over time
• Single–source
responsibility
• Nationwide network
Domestic Water Boosters
9What’s New
9“Notes
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 ththe 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: .4141 ->> .26
26
 VFD Protection

• VFD's up to 40 HP
inside a NEMA 1
enclosure
• Fan-cooled
Fan cooled with
positive pressure
• Thermostat-
Thermostat
controlled
• NEMA 12 Option
 VFD Benefits
• ENERGY SAVINGS
• Smooth hydraulics
• Pressure adjustment
• Maintenance of PRV’s
PRV s
• When recommended?
Demand  Annual  Current Current Annual  Future   Future  Future  kW
(GPM)
(GPM)  % Ti
% Time  H
Hours S
Sequencing
i P
Pump HP
HP kW S
Sequencing
i P
Pump HPHP kW S i
Savings

‐ 50% 4,380 Real Example

Pump 1  6.0 23,055  Off  0 ‐ 23,055 

1  5% 438 Pump 1  6.0 2,306  Pump 1  3 1,153  1,153 

40  10% 876 Pump 1  10.0 7,685  Pump 1  5 3,843  3,843 

80  10% 876 Pump 1  13.0 9,991  Pump 1  8 6,148  3,843 

120
120  10% 876 1&2
1 & 2  23 5
23.5 18 060
18,060  Pump 1
Pump 1  10 7 685 10,375 
7,685  10 375

140  8% 700  1 & 2  24.2 14,878  Pump 1  10 6,148  8,730 

160  3% 262  1 & 2  24.6 5,672  Pump 1  13.5 3,112  2,559 

200  1% 87 1 & 2  25.0 1,921  Pump 2  15 1,153  769 

220  1% 87 1 & 2  27.8 2,136  Pump 2  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
Pump 2  18 1 383
1,383  976
976 

280  1% 87  1 & 2  36.6 2,813  Pump 2  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 short-
circuit 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
Bernoulli’s
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 = 87 psig
( k S
(aka System
t Pressure)
P )
 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 spec’d)
 Protect Yourself!

This Not This

• System Pressure • Pump TDH
• Minimum Suction
• Maximum Suction

120 PSI Discharge 162’?

50 PSI Min
Min. S
Suction
ction 173’?
173 ?
70 PSI Maximum
Pressure Control
• Bottom Zone
• Zone PRV’s
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, 0
School,, Hotel

Hospital, Stadiums 1
 Example: Yankee Stadium
• 369 Women’s Toilets
• 98 Men’s Toilets
• 298 Men’s Urinals
• 150 Lavatories
• 50 Kitchens
369 Women’s Toilets
98 Men’s Toilets
298 Men’s Urinals
150 Lavatories
50 Kitchens
 E ti ti Flow
Estimating Fl

Fixture Type Count FU Total

T il t
Toilets 467 10 4670

Urinals 298 5 1490

Lavatories 150 2 300

Kitchens 50 4 200

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 Count FU Total

Bathroom 850 3.6 3060

Group
Bar Sink
S 850 1.4 1190

Mop Sink 68 3 204

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 • Flex-coupled
p End
End Suction Suction
• Vertical Turbine • Vertical Multistage
• Column-mounted • Horizontal Split
Turbines 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*
>900 gpm b
booster
t 3 – HSC 3 – VT

* If VFD
Pressure Control Options

• Variable Speed Pump

• Pressure
P R
Regulating
l ti
Valve
• Zone PRV’s 3-5 floors
q
• None Required
 Tank Sizing

• Higher in the building is better if no PRV’s

• 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 Boyle’s
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
_Story/BNP_GUID_9-5-
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