Pump and equipment optimization tool

Abstract

Systems and methods to facilitate selection and operation of different variable flow control mechanical devices and equipment for a specific system capacity having variable load. An example method includes: determining a load profile of the variable load; determining a design setpoint of the variable load; determining one or more candidate variable flow control mechanical devices, such as control pumps or control valves, which have a differential capability from the design setpoint; determining, for each of the one or more candidate variable flow control mechanical devices, one or more candidate equipment that are fulfilled by the differential capability; and calculating a respective cost of combinations of the one or more candidate variable flow control mechanical devices and the one or more candidate equipment operating together according to the load profile and the one or more candidate variable flow control mechanical devices operating at the differential capability from the design setpoint.

Description

PUMP AND EQUIPMENT OPTIMIZATION TOOLCROSS-REFERENCE

[0001] This application claims the benefit of priority to U.S. Patent Application No. 18 / 962941 filed November 27, 2024 entitled PUMP AND EQUIPMENT OPTIMIZATION TOOL, the entire contents of which are herein incorporated by reference into the Detailed Description herein below. This application is also a continuation-in-part of U.S. Patent Application No. 18 / 962941 filed November 27, 2024 entitled PUMP AND EQUIPMENT OPTIMIZATION TOOL.TECHNICAL FIELD

[0002] Example embodiments generally relate to Heating Ventilation and Air Conditioning (HVAC) systems, and selection and operation of equipment in HVAC systems.BACKGROUND

[0003] Heating Ventilation and Air Conditioning (HVAC) systems for a premises such as a building can contain central chilled water plants that are designed to provide air conditioning units with cold water as to reduce the temperature of the air that leaves the conditioned space before it is recycled back into the conditioned space during summer conditions. Similarly applicable for heating application where hot water from the boiler is used for heating the air in the building during winter conditions.

[0004] Chilled water plants are used to provide cold water or air for a building. Chilled water plants can comprise of active and passive mechanical equipment which work in concert to reduce the temperature of warm return water before supplying it to the distribution circuit. In chilled water plants, a heat exchanger is used to transfer heat energy between two or more circuits of circulation mediums. Similarly, a heating plant can include heat sources such as one or more boilers that provide hot water to the distribution circuit, from one or more boilers or from a secondary circuit having the heating source.

[0005] Some conventional industry practices may design heating, cooling and plumbing system performance around a single point that represented the most extreme conditions or loads that a building might experience during its operating lifecycle. A difficulty with some existing systems is that, at part-load, the pumping system may be susceptible to instability, poor occupant comfort and energy and economic wastage.

[0006] The traditional selection of a pump or pumps and associated equipment for a building may result in wastage of resources and inefficient operation. Load limits for a building may vary so that the equipment (e.g. pump, boiler plant, chiller, booster, heat exchanger, air separator, or other) may not be required to operate at full capacity to service the system requirements. Further, improper equipment selection may require a repair or total replacement of the equipment to a more suitable size of equipment (e.g. pump, boiler plant, chiller, booster, heat exchanger, air separator, or other). The operation of one equipment for a building affects the performance of another equipment that is operating in the same building.

[0007] In a typical process of selecting equipment for a system in the HVAC world, the equipment are sized independently from each other. Generally, the larger equipment are sized first (e.g. boiler, chiller, cooling tower) based on the building type, size and geographical location. Then follows the sizing of the pumps, as they serve both primary and secondary loops. Then, the heat transfer equipment and expansion equipment are only sized at the end taking into account the capacity they need to deliver. In this traditional way of designing the HVAC system, the heat transfer and expansion equipment can end up being unintentionally oversized as their relationship to the pumps is not always considered. Furthermore, the design of the heat transfer equipment (e.g. heat exchangers) traditionally only involves pump flow and a low pressure drop that does not necessarily account for the exact performance of the pump(s) that would be serving the heat exchanger and the HVAC system. Low pressure drop on a plate heat exchanger results in lower turbulence of the fluids and therefore leading to a lower heat transfer efficiency.

[0008] A typical reason for designing a heat exchanger with low pressure drop is to maintain lower pump operational energy costs. However, a drawback to this traditional methodology is lowering of the heat transfer efficiency as with lower pressure drops, theflow is not as turbulent therefore the heat does not transfer as effectively through the plates. To compensate for the lower heat transfer efficiency caused by the decreased turbulence in the fluids, the heat transfer area of the heat exchanger requires to be increased in order to meet the heat load requirements. In the case of a plate heat exchanger, this means more plates require to be added and therefore potentially oversizing the heat exchanger. As the primary construction of heat exchangers is metal, oversizing the heat exchanger also means higher capital costs. As well, an oversized plate heat exchanger due to a lower pressure drop can lead to lower fluid velocities which along with the lowered fluid turbulence allows for particulates and scaling materials to settle on the plate surface, resulting in fouling of the heat exchanger. As well, as a low pressure drop is designed based on a specific pump flow and head, if the flow rate changes significantly, the heat exchanger may not be able to maintain efficient heat transfer, resulting to a system underperforming, and therefore, leading to inefficient temperature control or heat recovery. If a heat exchanger has excessive pressure drop, then that means that the heat exchanger was not suitable sized and may not perform properly or efficiently.

[0009] Other difficulties with existing systems may be appreciated in view of the Detailed Description of Example Embodiments, herein below.SUMMARY

[0010] Example embodiments include systems and methods to facilitate selection and operation of different variable flow control mechanical devices and equipment for the specific system capacity having variable load. In some examples, the variable flow control mechanical devices include control pumps and / or control valves. In some examples, the equipment includes heat exchangers and / or air separators.

[0011] In examples, increasing the pressure drop on the heat exchanger can offer benefits but would increase the pump operational energy costs. Some of the benefits of increasing the pressure drop on the heat exchanger include higher heat transfer efficiency as the fluids are more turbulent. The turbulence of the fluids allows for heat to transfer more effectively through the plates and therefore, the surface area can bedecreased resulting in heat exchangers that are more cost and space efficient while the overall heat transfer efficiency of the heat exchanger is improved. Moreover, the increased turbulence can increase the heat exchanger's tolerance to fouling and allow for more viscous fluids to run through the heat exchanger effectively. Overall, increasing the pressure drop in a plate heat exchanger can significantly improve heat transfer performance, making the system more efficient and responsive, especially in applications where precise temperature control, compact design or viscous fluids are required.

[0012] Optimizing the pressure drop on the heat exchanger while maintaining reasonable pump operating energy costs is a very fine balance that can include iterations until an optimal solution is found. Traditionally, the more experienced engineers may perform manual computation by hand, but this is a very time-consuming process.

[0013] In other examples, decreasing the pressure setpoint of a pump and / or the pressure drop on the heat exchanger can reduce overall costs.

[0014] In examples, a controller is configured to facilitate and perform iterating between the different control pump and heat exchanger options available for the specific system capacity required. In examples, selection and optimization of control valves and air separators is also considered.

[0015] In some examples, the controller takes into account control pumps running on both sides of the heat exchanger (hot and cold fluids) as well as the heat exchanger, iterates between the different heads the control pumps can offer and how those can affect the heat exchanger pressure drop. The controller then computes between all the different combinations of control pumps and heat exchanger, their capital costs and operating energy costs over a pump lifetime, and provides a graphical user interface (e.g. user such as a design engineer, mechanical contractor, customer, sales agent, etc.) with a shortlisted and / or prioritized selection of control pumps and heat exchanger based on both capital and operational cost savings compared to a traditional base case selection. In some examples, the optimal combination is output to the graphical user interface.

[0016] The graphical user interface for selecting the appropriate equipment creates value to the user as the graphical user interface allow the selection to cater to their needs. For example, in some cases, first costs can be reduced by 10% by using thisgraphical user interface. Overall costs and operation costs over payback periods are also be considered by the controller.

[0017] An example embodiment is a method for a system having a variable load, the variable load being representable by a first parameter and a second parameter that are correlated, the method being performed by at least one processor and comprising: determining a load profile of the variable load; determining a design setpoint of the variable load; determining one or more candidate variable flow control mechanical devices which have a differential capability from the design setpoint, wherein the differential capability is a pressure variable; determining, for each of the one or more candidate variable flow control mechanical devices, one or more candidate equipment that are fulfilled by the differential capability; calculating a respective cost of combinations of the one or more candidate variable flow control mechanical devices and the one or more candidate equipment operating together according to the load profile and the one or more candidate variable flow control mechanical devices operating on a respective control curve having a respective setpoint which includes the differential capability from the design setpoint, including iteratively calculating by first iterating respective cost of the one or more candidate variable flow control mechanical devices, and second iterating, for the one or more candidate variable flow control mechanical devices from the first iterating, respective cost of the one or more candidate equipment; generating a priority based on the respective cost of the combinations; receiving selection of one of the combinations; and generating output for configuring the one or more candidate variable flow control mechanical devices of the one of the combinations that is selected with the respective control curve having the respective setpoint which includes the differential capability from the design setpoint.

[0018] Another example embodiment is a method for a system having a variable load, the method being performed by at least one processor and comprising: determining a load profile of the variable load; determining a design setpoint of the variable load; determining one or more candidate variable flow control mechanical devices which have a differential capability from the design setpoint, wherein the differential capability is a pressure variable; determining, for each of the one or more candidate variable flow control mechanical devices, one or more candidate equipment that are fulfilled by thedifferential capability; calculating a respective cost of combinations of one or more candidate variable flow control mechanical devices, one or more candidate heat exchangers, and one or more candidate air separators operating together according to the load profile and the one or more candidate variable flow control mechanical devices operating on a respective control curve having a respective setpoint which includes the differential capability from the design setpoint, including iteratively calculating by first iterating respective cost of the one or more candidate variable flow control mechanical devices, second iterating, for the one or more candidate variable flow control mechanical devices from the first iterating, respective cost of the one or more candidate heat exchangers, and third iterating, for the one or more candidate heat exchangers from the second iterating, respective cost of the one or more candidate air separators; generating a priority based on the respective cost of the combinations; receiving selection of one of the combinations; and generating output for configuring the one or more candidate variable flow control mechanical devices of the one of the combinations that is selected with the respective control curve having the respective setpoint which includes the differential capability from the design setpoint.

[0019] Another example embodiment is a system, comprising the at least one processor for performing the method of any one of the above.

[0020] Another example embodiment is a non-transitory computer readable medium having instructions stored thereon executable by at least one controller for performing the method of any one of the above.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments, and in which:

[0022] Figure 1 A illustrates a graphical representation of a building system, illustrated as a chilled water plant for providing cold water to a building, to which example embodiments may be applied.

[0023] Figure 1 B illustrates a graphical representation of further aspects of the chilled water plant shown in Figure 1 A.

[0024] Figure 1 C illustrates a graphical representation of another example chilled water plant, having a waterside economizer with a dedicated cooling tower, with parallel load sharing.

[0025] Figure 1 D illustrates a graphical representation of another example chilled water plant, having a waterside economizer with a dedicated cooling tower, with load sharing.

[0026] Figure 1 E illustrates a graphical representation of an example heating plant.

[0027] Figure 1 F illustrates a graphical representation of an example chilled water plant having a direct cooling loop.

[0028] Figure 1 G illustrates a graphical representation of an example heating plant having a district heating loop.

[0029] Figure 1 H illustrates a graphical representation of an example heating plant for heating potable water.

[0030] Figure 11 illustrates a graphical representation of an example building system for waste heat recovery.

[0031] Figure 1 J illustrates a graphical representation of an example building system for geothermal heating isolation.

[0032] Figure 2A illustrates a graphical representation of a heat exchanger, in accordance with an example embodiment.

[0033] Figure 2B illustrates a perspective view of an example heat transfer module with two heat exchangers, in accordance with an example embodiment.

[0034] Figure 2C illustrates a perspective view of an example heat transfer module with three heat exchangers, in accordance with an example embodiment.

[0035] Figure 2D illustrates a partial breakaway view of contents of the heat transfer module of Figure 2C.

[0036] Figure 2E illustrates a perspective view of an example heat transfer system that includes the heat transfer module of Figure 2C and two dual control pumps.

[0037] Figure 3A illustrates a graphical representation of network connectivity of a heat transfer system, having local setup.

[0038] Figure 3B illustrates a graphical representation of network connectivity of a heat transfer system, having remote setup.

[0039] Figure 4A illustrates a graph of an example heat load profile for a load such as a building.

[0040] Figure 4B illustrates a graphical user interface for configuring the load profile of Figure 4A, in accordance with an example embodiment.

[0041] Figure 4C illustrates a graph of an example flow load profile for a load such as a building.

[0042] Figure 4D illustrates a graphical user interface for configuring the load profile of Figure 4C, in accordance with an example embodiment.

[0043] Figure 5 illustrates a flow diagram of an example method for selection of equipment for operation in a heat transfer system, in accordance with an example embodiment.

[0044] Figure 6 illustrates an example flow diagram of a method for prioritizing and selecting equipment for operation in a heat transfer system.

[0045] Figure 7A illustrates a graph of an example range of operation and selection range of a variable speed control pump for a heat transfer system.

[0046] Figure 7B illustrates a graph of an example range of operation and selection range of a variable speed control pump for a heat transfer system, having an operating point: flow of 500 gpm (3.78 Ipm) and head of 115 ft (35 m).

[0047] Figure 7C illustrates a graph of the variable speed control pump of Figure 7B, having an operating point: flow of 500 gpm (3.78 Ipm) and head of 131 ft (40 m) (maximum head).

[0048] Figure 8A illustrates a graph of system head versus flow, having selection ranges for selecting of one or more candidate heat exchangers for a heat transfer system .

[0049] Figure 8B illustrates a graph of cooling capacity versus flow, having selection ranges for selecting of one or more candidate heat exchangers for a heat transfer system.

[0050] Figure 8C illustrates a graph of heating capacity versus flow, having selection ranges for selecting of one or more candidate heat exchangers for a heat transfer system.

[0051] Figure 9A illustrates a graphical user interface for selecting of control pumps and heat exchangers for a heat transfer system.

[0052] Figure 9B illustrates another graphical user interface for providing further parameters to those of Figures 9A for selecting of the control pumps and the heat exchangers for the heat transfer system.

[0053] Figure 10A illustrates a graphical user interface for outputting options of control pumps and heat exchangers for a heat transfer system.

[0054] Figure 10B illustrates a graphical user interface for outputting proposed equipment from the options for a heat transfer system.

[0055] Figure 10C illustrates a graphical user interface for outputting a proposal letter of the proposed equipment of Figure 10B.

[0056] Figure 11 A illustrates an air separator that is a coalescing style air and dirt separator, for selection and operation in the heat transfer system.

[0057] Figure 11 B illustrates an air separator that is a vortex style air separator, for selection and operation in the heat transfer system.

[0058] Figure 11 C illustrates a graph of an example range of operation and selection range of the coalescing style air and dirt separator of Figure 11 A.

[0059] Figure 12 illustrates an example block diagram of a communication system for facilitating selection of one or more equipment for operation in a heat transfer system, in accordance with an example embodiment.

[0060] Similar reference numerals may have been used in different figures to denote similar components.DETAILED DESCRIPTION

[0061] At least some example embodiments relate to processes, process equipment and systems in the industrial sense, meaning a process that outputs product(s) (e.g. hot water, cool water, air) using inputs (e.g. cold water, fuel, air, etc.). In such systems, a heat exchanger or heat transfer system can be used to transfer heat energy between two or more circuits (fluid paths) of circulation mediums. In some systems, an air separator can be used to remove air (and sometimes dirt) from the circulation medium.

[0062] At least some example embodiments relate to the operating of equipment in a system such as an HVAC system, temperature control system, heat transfer system, hydronic system, or flow control system, and selection of such equipment that has appropriate and efficient capacity and cost for installation and operation in the system.

[0063] Many building systems do not operate at full load (duty load). In an example embodiment, a controller can be configured for facilitation selection of equipment for operation in the building system.

[0064] Figure 1A illustrates an example building system 100 such as a chilled water plant, in accordance with an example embodiment. In an example, the building system 100 is a HVAC building system. As shown in Figure 1A, the building system 100 can include, for example: one control pump 102a for load, one chiller 120, one control pump 102b for source, an air separator 132, and two cooling towers 124. In an example embodiment, more or fewer numbers of device can exist within each equipment category. Other types of equipment, rotary devices, and flow control devices (e.g. valves) may be included in the building system 100.

[0065] The building system 100 can be used to source a building 104 (as shown), campus (multiple buildings), premises, district, vehicle, plant, generator, heat exchanger, or other suitable infrastructure or load, with suitable adaptations. The control pump 102a may include one or more respective pump devices 106a (one shown here, whereas two pump devices for a single control pump 102a are illustrated in Figure 2E) and a control device 108a for controlling operation of the pump device 106a. The control pump 102bcan have a variably controllable motor, and can include a pump device 106b and a control device 108b. The particular circulation medium may vary depending on the particular application, and may for example include glycol, water, air, fuel, and the like. The chiller 120 can include at least a condenser and an evaporator, for example, as understood in the art. The condenser of the chiller 120 collects unwanted heat through the circulation medium before the circulation medium is sent to the cooling towers 124. The chiller 120 itself is (or is part of) a heat exchanger, and examples embodiments that refer to a heat exchanger can be applied to the chiller 120, as applicable. The evaporator of the chiller 120 is where the chilled circulation medium is generated, and the chilled circulation medium leaves the evaporator and is flowed to the building 104 by the control pump 102a. Each cooling tower 124 can be dimensioned and configured to provide cooling by way of evaporation, and can include a respective fan, for example. Each cooling tower 124 can include one or more cooling tower cells, in an example.

[0066] The building system 100 can be configured to provide air conditioning units of the building 104 with cold water to reduce the temperature of the air that leaves the conditioned space before the air is recycled back into the conditioned space. The building system 100 can comprise of active and passive mechanical equipment which work in concert to reduce the temperature of warm return water before supplying it to the distribution circuit.

[0067] Referring to Figure 1 B, the building system 100 may include a heat exchanger 118 which is an interface in thermal communication with a secondary circulation system, for example via the chiller 120 (Figure 1 A), ambient, or a temperature source. The heat exchanger 118 can be placed in various positions in the building system 100 of Figure 1 B. The air separator 132 can be placed in various positions in the building system 100 of Figure 1 B, and is typically positioned upstream of the control pump 102a. The building system 100 may include one or more loads 110a, 110b, 110c, 110d, wherein each load 110a, 110b, 110c, 110d may be a varying usage requirement based on requirements of an air conditioner, HVAC, plumbing, etc. Each 2-way valve 112a, 112b, 112c, 112d may be used to manage the flow rate to each respective load 110a, 110b, 110c, 110d. In some example embodiments, as the differential pressure across the load decreases, the control device 108a responds to this change by increasing the pumpspeed of the pump device 106a to maintain or achieve the output setpoint (e.g. pressure or temperature). If the differential pressure across the load increases, the control device 108a responds to this change by decreasing the pump speed of the pump device 106a to maintain or achieve the setpoint. In some example embodiments, an applicable load 110a, 110b, 110c, 110d can represent cooling coils to be sourced by the circulation medium the chiller 120, each with associated valves 112f, 112b, 112c, 112d, for example. In some examples, an applicable load 110a, 110b, 110c, 110d can represent fan coils that each include a cooling coil and a controllable fan (not shown) that blows air across the coiling coils. In some examples, the fan has a variably controllable motor to control temperature in the region to be cooled. In other examples, the fan has a binary controllable motor (e.g., only on state or off state) to control temperature in the region to be cooled. The control devices 108a and the control valves 112a, 112b, 112c, 112d can respond to changes in the chiller 120 by increasing or decreasing the pump speed of the pump device 106a, or variably controlling an amount of opening or closing of the control valves 112a, 112b, 112c, 112d, or control of the fans, to achieve the specified output setpoint.

[0068] In Figure 1A, the control pump 102b (more than one control pump is possible) is used to provide flow control from the cooling towers 124 to the chiller 120 (which can include the heat exchanger 118). In various examples, the control pump 102b can be used to control flow from a cooling or heating source to the heat exchanger 118. In some examples, the heat exchanger 118 is separate from the chiller 120. In other examples, the chiller 120 is integrated with the heat exchanger 118. In some examples, the heat exchanger 118 is integrated with one or both control pumps 102a, 102b (e.g., see Figure 2E). In other examples, the heat exchanger 118 is separated from the control pumps 102a, 102b using piping, fittings, intermediate devices, etc. The control pumps 102a, 102b can be referred to as variable control pumps. The control pumps 102a, 102b are variable flow control mechanical devices. Other types variable flow control mechanical devices can be used in other example embodiments, such as variable control valves or pressure independent control valves (PICVs). In an example, not shown here, the secondary circulation system sourced by the control pump 102b can also include a respective air separator 132.

[0069] Referring to Figure 1 B, the output properties of each control pump 102a, 102b can be controlled to, for example, achieve a temperature setpoint or pressure setpoint at the combined output properties represented or detected by external sensor 114, shown at the load 110d at one point of the building 104 (e.g., the highest point in this example). The external sensor 114 represents or detects the aggregate or total of the individual output properties of all of the control pumps 102a, 102b at the load, in one example, flow and pressure. Information on flow and pressure local to the control pump 102a, 102b can also be represented or detected by a respective sensor 130, in an example embodiment. The external sensor 114 can be used to detect temperature and heat load (Q) in example embodiments. Heat load (Q) can refer to a hot temperature load or a cold temperature load. In an example, the external sensor 114 for temperature and heat load can be placed at each load (110a, 110b, 110c, 11 Od), or one external sensor 114 is placed at the highest point at the load 110d. Other example operating parameters are described in greater detail herein.

[0070] One or more controllers 116 (can be generally denoted controller 116), which can include one or more processors, may be used to coordinate the output (e.g. temperature, pressure, and flow) of some or all of the devices of the building system 100. The controllers 116 can include a main centralized controller in some example embodiments, and / or can have some of the functions distributed to one or more of the devices in the overall system of the building system 100 in some example embodiments. In an example embodiment, the controllers 116 are implemented by a processor which executes instructions stored in memory. In an example embodiment, the controllers 116 are configured to control or be in communication with the loads (110a, 110b, 110c, 110d), the valves (112a, 112b, 112c, 112d), the control pumps 102a, 102b, the heat exchanger 118, and other equipment and devices.

[0071] Referring again to Figures 1A and 1 B, in some example embodiments, the building system 100 can represent a heating circulation system (“heating plant”), with suitable adaptation. The heating plant may include a heat exchanger 118 which is an interface in thermal communication with a secondary circulation system, such as a boiler system. Instead of a chiller 120, the boiler system can include one or more boilers 140 (not shown here). In an example, control valves 112a, 112b, 112c, 112d manage the flowrate to heating elements (e.g., loads 110a, 110b, 110c, 110d). The control devices 108a, 108b and the control valves 112a, 112b, 112c, 112d can respond to changes in the heating elements (e.g., loads 110a, 110b, 110c, 110d) and the boiler system by increasing or decreasing the pump speed of the pump device 106a, or variably controlling an amount of opening or closing of the control valves 112a, 112b, 112c, 112d, to achieve the specified output setpoint (e.g., temperature or pressure). In some examples, the one or more boilers 140 is separate from the heat exchanger 118. In other examples, the one or more boilers 140 is integrated with the heat exchanger 118. In other examples, other heat sources or cooling sources can be used to source the secondary circulation system.

[0072] Each control device 108a, 108b can be contained in a Pump Controller card 226 (“PC card”) that is integrated within the respective control pump 102a, 102b. A controller (with communication device) of the heat exchanger 118 can be contained in a Heat exchanger card 222 (“HX card”) that is integrated within the heat exchanger 118. In an example, the PC card 226 can be a tablet style device that includes a touch screen, processor, and communication subsystem, that can be stand alone manufactured and then integrated into the respective control pump 102a, 102b. The HX card 222 is integrated with heat exchanger 118, and can be a similar tablet style device as the PC card 226 having a touch screen 228 in some examples, and in some examples does not have the touch screen 228. In an example, the PC card 226 can be the control device 108a, 108b of the control pump 102a, 102b (Figure 1A).

[0073] Figure 1 C illustrates a graphical representation of another example chilled water plant, having a waterside economizer with a dedicated cooling tower 124, with parallel load sharing, in accordance with an example embodiment. In this example, the cooling tower 124 sources the chiller 120 and the heat exchanger 118 in parallel. The load 110a, 110b, 110c, 110d is an air conditioner load that is sourced by the chiller 120 and the heat exchanger 118 in parallel.

[0074] In the configuration of Figure 1 C, the supply flow is usually run at full speed. Since the cooling tower 124 operation is relatively cheap compared to running a chiller 120, running the maximum flow through the cooling tower 124 is preferred. In cases where the cooling tower 124 is used in part loads, then controlling Tload, supply or using a Maximize Source Side Delta T with constant temperature approach and constant loadside Delta T is recommended to ensure that the load side is getting their design temperatures. To get additional savings, the user can define the minimum approach between Tsource, in and Tload, out using the Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. An example approach temperature of 1 F (or applicable delta in Celsius) can be used so that pump energy is not consumed if additional heat exchange is too low.

[0075] Figure 1 D illustrates a graphical representation of another example chilled water plant, having a waterside economizer with a dedicated cooling tower 124, with load sharing, in accordance with an example embodiment. The cooling tower 124 sources the heat exchanger 118. The heat exchanger 118 provides cooled circulation medium to the chiller 120. The chiller provides further temperature reduction and sources the load 110a, 110b, 110c, 11 Od, which is an air conditioner load. The heat exchanger 118 can also directly source the load 110a, 110b, 110c, 110d by way of chiller bypass piping, as shown.

[0076] Since the chiller 120 uses the most energy in the system 100, it is advantageous for the control pump 102b to run full speed. In cases where the cooling tower 124 is used in part loads, then controlling Tload, supply or using a Maximize Source Side Delta T with constant temperature approach and constant load side Delta T is recommended to ensure that the load side is getting their design temperatures. To get additional savings, the user can define the minimum approach between Tsource, in and Tload, out using a Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. An approach temperature of 1 F (or applicable delta in Celsius) is recommended so that pump energy is not consumed if additional heat exchange is too low.

[0077] An input on the pump is reserved that allows the system 100 to switch between load sharing and running the cooling tower 124 by itself.

[0078] In another example, not shown here, a vehicle system can include a similar system for an air conditioner of a vehicle, in accordance with an example embodiment. The air conditioner, that includes a compressor and condenser, circulates a coolant through the heat exchanger 118 in order to cool ambient air or recirculated air to thepassenger interior of the vehicle. The cool ambient air can pass through bypass piping or valves to bypass the heat exchanger 118 in some examples.

[0079] Figure 1 E illustrates a graphical representation of an example heating plant, in accordance with an example embodiment. The heating plant includes a boiler 140 that sources the heat exchanger 118. The heat exchanger 118 transfers heat energy to the loads 110a, 110b, 110c, 110d, which can be parallel loads that are perimeter heating units.

[0080] When the boiler 140 is a condensing boiler, the efficiency of the boiler 140 increases as the return water temperature is lower. To attain the lowest return temperature, the source side flow should be minimized without affecting the load side too adversely. The recommended control methods would be to Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. Further energy efficiency improvements can be obtained using Maximize Source Side Delta T with variable temperature approach and variable load side Delta T if the user is flexible with varying Tload, out.

[0081] For non-condensing boilers, the efficiency does not vary much with return temperature, therefore, the recommend method is Maximize Source Side Delta T with constant temperature approach and constant load side Delta T.

[0082] Figure 1 F illustrates a graphical representation of an example chilled water plant having a direct cooling loop, in accordance with an example embodiment. The chiller 120 sources the heat exchangers 118 that are in parallel. The chiller 120 includes a condenser and an evaporator. Each heat exchanger 118 transfers heat energy for providing cooled circulation medium to each respective load 110a, 110b, 110c, 110d. The loads 110a, 110b, 110c, 110d can represent air handling units on a respective floor or zone.

[0083] In the configuration of Figure 1 F, the chiller 120 controls the supply temperature, which can be based on ASHRAE (RTM) 90.1. For the chiller 120, a higher return temperature leads to more efficient operation (approximately 2% efficiency improvement per 1 F higher, or equivalent delta Celsius). The recommended control method is Tload, out control or Maximize Source Side Delta T with constant temperatureapproach and constant load side Delta T. Further energy efficiency improvements can be obtained using Maximize Source Side Delta T with variable temperature approach and variable load side Delta T if the user is flexible with varying Tload, out.

[0084] A similar configuration of Figure 1 F can be used for a direct heating loop, in other examples. For condensing boilers 140, the recommended control methods would be Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. Further energy efficiency improvements can be obtained using Maximize Source Side Delta T with variable temperature approach and variable load side Delta T if the user is flexible with varying Tload, out. For non-condensing boilers 140, the efficiency does not vary much with return temperature, therefore, the recommend method is Maximize Source Side Delta T with constant temperature approach and constant load side Delta T.

[0085] Figure 1 G illustrates a graphical representation of an example heating plant having a district heating loop, in accordance with an example embodiment. The district can be multiple buildings 104. A boiler 140 is used to source the heat exchangers 118 that are in parallel, for example one heat exchanger 118 per respective building 104. Each heat exchanger 118 transfers heat energy to a respective load 110a, 110b, 110c, 110d for each building 104. A similar configuration can be used for a district cooling loop, in other examples.

[0086] In this configuration, the source side control pump 102b is sometimes replaced by a smart energy valve when the application requires. An optimization method is to return the highest temperature on the source side in cooling and return the lowest source side temperature in heating. The recommend control method is Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. Further energy efficiency improvements can be obtained using Maximize Source Side Delta T with variable temperature approach and variable load side Delta T if the user is flexible with varying Tload, out.

[0087] Figure 1 H illustrates a graphical representation of an example heating plant for heating potable water, in accordance with an example embodiment. The boiler 140 can be a hot water boiler that sources the heat exchanger 118. The heat exchanger 118 transfers heat energy potable water to a hot water storage tank 142, for sourcing heatedpotable water to the load 110a, 110b, 110c, 110d, which can be faucets, taps, etc. In this configuration the hot water storage tank 142 would usually be required to be kept at a constant temperature. An example control method would be to control Tload, out.

[0088] Figure 11 illustrates a graphical representation of an example building system 100 for waste heat recovery, in accordance with an example embodiment. A heat source such as a computer room has heat removed by way of a circulation medium to the heat exchanger 118, in order to cool the computer room. The heat exchanger 118 then transfers the heat to any water to be preheated. In this mode the heat recovery is to be used as much as possible. An example method is to maximize Delta T between Tload, in and Tload, out. Another example method is to control Tsource, out for a desired return temperature. Note that reference to “source” and “load” may be switched here, depending on the particular perspective.

[0089] In another example, a vehicle system can include a similar system for waste heat recovery, in accordance with an example embodiment. A heat source such as an engine of a vehicle has heat removed by way of a circulation medium to the heat exchanger 118, in order to cool the engine. The heat exchanger 118 then transfers the heat to air of the air circulation system to the passenger interior of the vehicle.

[0090] Figure 1 J illustrates a graphical representation of an example building system 100 for geothermal heating isolation, in accordance with an example embodiment. A heat source such as geothermal is used to heat a circulation medium to the heat exchanger 118. The heat exchanger 118 then transfers the heat to provide hot, clean water to the load(s) 110a, 110b, 110c, 110d. In this configuration, it is desired that as much heat is transferred without leaving Tsource, out too cold as it can harm the living organisms in the vicinity. In this case, Tsource, out can be controlled with a minimum temperature set.

[0091] If any of the four temperature sensors which measure the port inlet temperatures on the hot and cold side of the heat exchanger 118 are not available or out of range, then the pump controls on the source side control pump 102b can default to constant speed and the pump controls on the load side control pump 102a can default to so-called sensorless mode, described in greater detail herein.

[0092] Figure 2A illustrates a graphical representation of the heat exchanger 118, in accordance with an example embodiment. The heat exchanger 118 is a plate type counter current heat exchanger in an example. The heat exchanger 118 includes a frame 200 that is a sealed casing. The heat exchanger 118 defines a first fluid path 204 (of a first fluid circuit) for a first circulation medium, and a second fluid path 206 (of a second fluid circuit) for a second circulation medium. The first fluid path 204 is not in fluid communication with the second fluid path 206. The first fluid path 204 is in thermal contact with the second fluid path 206. The first fluid path 204 can flow in an opposing flow direction (counter current) to the second fluid path 206. In an example, the heat exchanger 118 is a brazed plate heat exchanger (BPHE). A plurality of brazed plates 202 are parallel plates that facilitate heat transfer between the first fluid path 204 and the second fluid path 206. The first fluid path 204 and the second fluid path 206 flow between the brazed plates 202, typically the first fluid path 204 and the second fluid path 206 are in alternating fluid paths of the brazed plates 202. The plurality of brazed plates 202 are dimensioned with braze patterns for causing turbulence to promote heat transfer between the first fluid path 204 and the second fluid path 206. Turbulent flow in the heat exchanger 118 is increased (decreases probability of turbulent flow), and as a result there is a higher pressure drop across the heat exchanger 118. Turbulent flow promotes loosing of fouling on the braze patterns of the brazed plates 202. For a smaller heat exchanger 118 (which uses less material), a higher pressure drop increases turbulent flow (decreases probability of turbulent flow) but also requires higher pump energy consumption. In other examples, the heat exchanger 118 is a shell and tube (S&T) type heat exchanger, or a gasketed plate heat exchanger (PHE)).

[0093] The load side is the side that is connected to the load requiring heat such as a building or room. Variable flow through the load side is controlled by the control pump 102a. The source side is connected to the source of heat that is to be transferred such as the chiller 120, boiler 140, or district source. Variable flow through the source side is controlled by the control pump 102b. There are two conventions that can be used to notate parameters in heat transfer loops. The first convention, parameters such as temperature and flow are taken with reference to the heat exchanger 118. That is, for example, the water temperature going in to the heat exchanger 118 from the source sideis called Tsource, in. The water temperature going out of the heat exchanger 118 from the source side is called Tsource, out.

[0094] An alternate convention is that parameters are notated such that, on the source side, the supply is taken as the fluid provided from the source to the heat exchanger 118 and the return is taken as the fluid returned to the source. For the load side, the supply is taken as the fluid provided to the load and the return is the fluid returned from the load. This is taken from chiller and fan coil conventions. For the purpose of calculations, examples herein will mainly refer to the first convention referencing the in and out looking from the heat exchanger 118.

[0095] In example embodiments, any or all of control pumps 102a, 102b can be replaced with, or used in combination with, other types of variable flow control mechanical devices such as variable control valves or pressure independent control valves (PICVs). For example, in example embodiments, rather than the load side control pump 102b, another type of flow control mechanical device such as a variable control valve is used instead of the control pump 102b. The source side can be connected to the source of heat that is to be transferred such as the chiller 120, boiler 140, or district source, which may have their own pumps (not necessarily controllable by the controllers 116) and provide a constant or variable flow to the heat exchanger 118. The variable flow on the source side of the heat exchanger 118 is controlled by the variable control valve. Information detected by one or more of the described sensors can be used to determine the variable control of the variable control valve (e.g., the amount of opening), to achieve the desired amount of flow. For example, municipal flow has a variable source pressure to the heat exchanger 118, and the variable control valve can be used to control the flow to the heat exchanger.

[0096] In an example, not shown, the variable control valve includes a controller and a variable valve that is controlled by the controller. The controller of the variable control valve can be configured for communication with the controllers 116, for example to receive instructions on the variable amount of opening or flow, and for example to send the current status of the variable amount of opening or flow. The variable control valve can include a variably controllable ball valve in some examples. Other example variable control valves include cup valves, gear valves, screw valves, etc. The variable controlvalve can include onboard sensors, and may perform self-adjustment, monitoring and control using its controller. The variable control valve can be pressure independent in some examples. The variable control valve can be a 2-way variable control valve in some examples.

[0097] The frame 200 of the heat exchanger 118 can include four ports 208, 210, 212, 214, as shown in Figure 2A. Port 208 is for Source, In or Source, Supply. Port 210 is for Source, Out or Source, Return. Port 212 is for Load, Out or Load, Supply. Port 214 is for Load, In or Load, Return. In an example, the frame 200 is an integrated sealed casing that cannot be disassembled, because maintenance is performed by way of flushing through the ports 208, 210, 212, 214.

[0098] Various sensors can be used to detect and transmit measurement of the heat exchanger 118. The sensors can include sensors that are integrated with the heat exchanger 118, including sensors for: Temperature Source, In (TSource, In);Temperature Source, Out (TSource, In); Temperature Load, Out (TLoad, Out); Temperature Load, In (TLoad, In); Differential Pressure between Source, In and Source, Out; Differential Pressure between Load, In and Load, Out; Pressure at Source, In; Pressure at Load, In. More or fewer of the sensors can be used in various examples, depending on the particular parameter or coefficient being detected or calculated, as applicable. In some examples, the sensors include flow sensors for: Flow, source (Fsource); and Flow, load (Fload), which are typically external to the heat exchanger 118, and can be located at, e.g., the control pump 102a, 102b, or the external sensor 114, or the load 110a, 110b, 110c, 110d.

[0099] Baseline measurement from the sensors is stored to memory for comparison with subsequent real-time operation measurement from the sensors. The baseline measurement can be obtained by factory testing using a testing rig, for example. In some examples, the baseline measurement can be obtained during real-time system operation.

[0100] Example embodiments include a heat transfer module that can include one or more heat exchangers 118 within a single sealed casing (frame 200), wherein Figure 2B illustrates a heat transfer module 220 with two heat exchangers 118 and Figures 2C and 2D illustrate a heat transfer module 230 with three heat exchangers 118.

[0101] Figure 2E illustrates a heat transfer system 240 that includes the heat transfer module 230 and control pumps 102a, 102b. In examples, the heat transfer module can include one, two, three or more heat exchangers 118 within the single sealed casing (frame 200). The heat transfer system 240 provides a reliable and optimized heat transfer solution comprised of heat exchanger(s) 118 and control pumps 102a, 102b by providing an optimized heat transfer system solution rather than providing equipment sized for duty conditions only. The heat transfer system 240 can be used for liquid to liquid HVAC applications with typical applications in residential, commercial, industrial and public buildings, district heating or cooling, etc. Applications include cooling, heating, water side economizer (e.g., cooling tower), condenser isolation (e.g., lake, river, or ground water), district heating and cooling, pressure break, boiler heating, thermal storage, etc. The heat transfer system 240 can be shipped as a complete package or optionally shipped in modules that can be quickly assembled on site.

[0102] Figure 2B illustrates a perspective view of the heat transfer module 220 with two heat exchangers 118a, 118b, in accordance with an example embodiment. The heat transfer module 220 includes a HX card 222 for receiving measurement from the various sensors of the heat transfer module 220, determining that maintenance is required on the heat transfer module 220, and communicating that maintenance is required to the controllers 116 or the control pumps 102a, 102b. Shown are ports 208, 210, 214, note that port 212 is not visible in this view in Figure 2B. A touch screen 228 can be used as a user interface for user interaction with the respective heat transfer module 220. The touch screen 228 can be integrated with the HX card 222, for example, in a tablet computer style device.

[0103] Each heat exchanger 118a, 118b can have one or more respective shutoff valves 224 that are controllable by the HX card 222. Therefore, each heat exchanger 118a, 118b within the heat transfer module 220 is selectively individually openable or closable by the HX card 222. In the examples shown, there are four shutoff valves across 224 each heat exchanger 118a, 118b.

[0104] The various sensors can be used to detect and transmit measurement of parameters of the heat transfer module 220. The sensors can include temperature sensors for Temperature Source, In (TSource, In); Temperature Source, Out (TSource,In); Temperature Load, Out (TLoad, Out); Temperature Load, In (TLoad, In). The temperature sensors can further include temperature sensors, one each for respective Temperature output of the source and load fluid path of each heat exchanger 118a, 118b (four total in this example). Therefore, eight total temperature sensors can be used in the example heat transfer module 220.

[0105] The sensors can also include sensors for: Differential Pressure between Source, In and Source, Out; Differential Pressure between Load, In and Load, Out; Pressure at Source, In; Pressure at Load, In. More or fewer of the sensors can be used in various examples, depending on the particular parameter or coefficient being detected or calculated, as applicable. Such sensors can be contained within the sealed casing (frame 200). In some examples, the sensors include flow sensors for: Flow, source (Fsource); and Flow, load (Fload), which are typically external to the heat transfer module 220.

[0106] Figure 2C illustrates a perspective view of the heat transfer module 230 with three heat exchangers 118a, 118b, 118c, in accordance with an example embodiment. Figure 2D illustrates a partial breakaway view of contents of the heat transfer module 230, shown without the frame 200. As can be seen in Figure 2D, the plurality of brazed plates 202 of each of the heat exchangers 118a, 118b, 118c are oriented vertically.

[0107] The heat transfer module 220 includes the HX card 222 for receiving measurement from the various sensors of the heat transfer module 220, determining that maintenance is required on the heat transfer module 220, and communicating that maintenance is required to the controllers 116 or the control pumps 102a, 102b. Shown are ports 208, 210, 214, note that port 212 is not visible in this view. The various sensors can be used to detect and transmit measurement of parameters of the heat transfer module 230, with such sensors described above in relation to the heat transfer module 220 (Figure 2B) having the two heat exchangers 118a, 118b. For example, ten total temperature sensors can be used in the example heat transfer module 230, e.g., one for each port 208, 210, 212, 214 (four total), one for each output of each heat exchanger 118a, 118b, 118c of the source path (three total), and one for each output of each heat exchanger 118a, 118b, 118c of the load path (three total).

[0108] Figure 2E illustrates a perspective view of an example heat transfer system 240 that includes the heat transfer module 230 of Figure 2C and two control pumps 102a, 102b. The control pumps 102a, 102b are each dual control pumps that each have two pump devices in a single casing, as shown. A dual control pump allows for redundancy, standby usage, pump device efficiency, coordinated control, etc. The dual control pump can have two separate PC cards 226 in some examples. A similar configuration can be used for the heat transfer module 220 of Figure 2B or a single heat exchanger 118 as in Figure 2A. As shown in Figure 2E, control pump 102a is connected to port 212 for Load, Out or Load, Supply. Control pump 102b is connected to port 208 for Source, In or Source, Supply. In other examples, the control pumps 102a, 102b are not directly connected to each port 212, 208 but are rather upstream or downstream of each port 212, 208, and connected through intermediate piping, or other intermediate devices such as strainers, in-line sensors, valves, pressure independent control valves (PICVs), fittings, tubing, suction guides, boilers, or chillers.

[0109] The heat transfer module 230 has a dedicated HX card 222 with WIFI communication capabilities. The HX card 222 can be configured to store a heat transfer performance map of each heat exchanger 118a, 118b, 118c in the heat transfer module 230, based on factory testing. The HX card 222 can poll data from the ten temperature sensors, two pressure sensors, and two differential pressure sensors. The HX card 222 can also poll flow measurement data from the two control pumps 102a, 102b. If the control pumps 102a, 102b are nearby and able to communicate via WIFI (via PC card 226), then data is polled directly from the control pumps 102a, 102b, otherwise flow measurement data is collected using wired connection or through the Local Area Network. The control pumps 102a, 102b can receive data from the HX card 222 and show, on the pump display screen, the inlet and outlet temperature of the fluid that the control pump 102a, 102b is pumping and the differential pressure across the heat transfer module 230.

[0110] The various sensors allow the controllers 116 to calculate heat exchanged in real time based on the flow measurement (determined by the control pumps 102a, 102b or external sensor 114) and temperatures on each side of the heat transfer module 230. Additionally, for heat transfer modules with two or three heat exchangers 118, eachbranch on the outlet connection can have a temperature sensor to allow fouling / clogging prediction in each individual heat exchanger 118. For each heat exchanger 118, data collected by the HX card 222 and pump PC cards 226 can be used to calculate overall heat transfer coefficient (U value) in real time and compare that with the overall clean heat transfer coefficient (llclean) to predict fouling and need for maintenance I cleaning. The collected data will be used to calculate total heat transfer in real time and optimized system operation to minimize energy costs (for pumping and on the source) while meeting load requirements. Internet connectivity will be achieved through the dedicated HX card 22 and pump PC card 226. Data is uploaded to the Cloud 308 for data logging, analysis, and control.

[0111] Suction guides (not shown) can be integrated in the heat transfer module220, 230 with a strainer having a #20 grade (or greater) standard mesh. In an example, the suction guide is a multi-function pump fittings that provide a 90° elbow, guide vanes, and an in-line strainer. Suction guides reduce pump installation cost and floor space requirements. If the suction guide is not available, then a Y-Strainer with the proper mesh can be included. Alternatively, a mesh strainer can be installed on the source side.

[0112] Figure 3A illustrates a graphical representation of network connectivity of a heat transfer system 300, having local system setup. The heat transfer system 300 includes a Building Automation System (BAS) 302 that can include the controllers 116 (Figures 1A and 1 B). The BAS 302 can communicate with the control pumps 102a, 102b and the heat transfer module 220 by a router 306 or via short-range wireless communication. A smart device 304 can be in communication, directly or indirectly, with the BAS 302, the control pumps 102a, 102b and the heat transfer module 220. The smart device 304 can be used for commissioning, setup, maintenance, alert / notifications, communication and control of the control pumps 102a, 102b and the heat transfer module 220. In examples, the smart device 304 can be a smart phone or mobile communication device.

[0113] Figure 3B illustrates a graphical representation of network connectivity of a heat transfer system 320, having remote system setup. The BAS 302 can communicate with the control pumps 102a, 102b and the heat transfer module 220 by a router 306 or via short-range wireless communication. The smart device 304 can access, by way ofInternet connection, one or more cloud computer servers over the cloud 308. The smart device 304 can be in communication, directly or indirectly with the BAS 302, the control pumps 102a, 102b and the heat transfer module 230 over the cloud 308. The smart device 304 can be configured for commissioning, setup, maintenance, alert / notifications, communication and control of the control pumps 102a, 102b and the heat transfer module 230. The cloud servers store an active record of measurement of the various equipment, and their serial numbers. When maintenance and service is required, records and notes can be viewed. This can be part of a service application (“app”) for the smart device 304.

[0114] Each heat transfer module 230 can have a HX card 222. The function of the HX card 222 is to connect to all sensors and devices on the heat transfer module 230 either through a physical connection (Controller Area Network (CAN) bus or direct connection) and / or wirelessly. The HX card 222 can also collect information from the pump PC card 226 either through a physical connection or wirelessly.

[0115] The HX card 222 gathers all of the sensor measurement and other information and processes it and controls the flow required to the source side control pump 102b. The HX card 222 also sends sensor readings to the source side control pump 102b and the load side control pump 102a so that they can display real-time information on their respective display screens(s). The HX card 222 can also send the sensor measurement information to the Cloud 308. In an example, all heat exchanger related calculations can be handled by the HX card 222 for more immediate processing. In an example, the other devices can be configured as devices for displaying data previous calculated by the HX card 222.

[0116] The user can modify settings by connecting to the HX card 222 locally using the wireless smart device 304 or the BAS 302. The user can also modify limited settings remotely by connecting to the Cloud 308. These settings will be limited depending on security restrictions.

[0117] When the HX card 222 and the control pumps 102a, 102b are connected through the router 306, then the smart device 304, the PC card 226 and the HX card 222 can communicate using the router 306. When the HX card 222 and the control pumps 102a, 102b are not connected through on the router 306, then the HX card 222 canautomatically open a WIFI hotspot for communication between the smart device 304, PC card 226 and HX card 222. When the HX card 222 opens the WIFI hotspot, communication to the Cloud 308 can occur either through the built in loT card, Ethernet connection, SIM card, etc.

[0118] The PC card 226 can connect to the HX card 222 either wirelessly or through a physical connection and provide the HX card 222 with pump sensor data. The PC card 226 can receive data from the HX card 222 (measurement, alerts, calculations) to be displayed on the pump display screen.

[0119] The PC card 226 can communicate to the HX card 222 wirelessly using the ModBUS protocol, as understood in the art. Other protocols can be used in other examples. For communication to occur between the PC card 226 and the HX card 222, the IP addresses of the PC card 226 and the HX card 222 need to be known. Internal identifiers can also be built into the PC card 226 and the HX card 222 such that they can find each other easily on a local area network. The PC card 226 can send information to other devices and accepting information and control from other devices.

[0120] The BAS 302, when used, can connect to the HX card(s) 222 and the PC card(s) 226 wirelessly through the router or through a direct connection. In an example, the BAS 302 has the highest control permissions and can override the HX card(s) 222 and the PC card(s) 226.

[0121] The HX card 222 provides to the Cloud 308 historic measurement data for storage. There can an application on the smart device 304 where the user can view data and generate reports. The Cloud 308 can use historic data to create reports and provide performance management services.

[0122] The smart device 304 can connect locally through the router 306 to the HX card 222 to modify settings. The smart device 304 can also connect to the Cloud 308 where the user can modify a limited number of settings, in an example.

[0123] An application (App), webserver user interface, and / or website can be included so that the user has all the functionality available on the PC card 226 or the Cloud 308. See, for example, Figure 12.

[0124] The heat transfer system 300, 320 can be configured to provide information to users through the PC card 226, and remotely through online services and a control pump manager. The inputs to the HX card 222 can collect readings and measurements from the two temperature sensors on the cold side fluid and the two temperature sensors on the hot side fluid across the entire heat transfer module 230. Duplex and triplex heat transfer modules 220, 230 can have additional temperature sensors on the outlets of each individual heat exchanger 118a, 118b, 118c to calculate the temperature difference across the single heat exchanger 118a, 118b, 118c. The absolute temperature difference between the two temperature sensors is called the delta T. The HX card 222 and PC card 226 can communicate in real time and provide the data to the Cloud 308 for data logging and processing.

[0125] The heat transfer system 300, 320 can operate using demand based controls. Changes in the heat load in the building (load side, in general) will result in changes in flow requirement. In some examples, the control pump(s) 102a on load side will adjust speed to meet the flow requirement in real time based on sensorless (e.g., parallel or coordinated sensorless) operation. In some examples, the control pump 102a calculates the flow in real time and the HX card 222 gets signals from temperature sensors installed on inlet and outlet of heat exchanger(s) 118. The temperature difference is calculated in real time on the HX card 222 and together with flow used to calculate heat load (Q) required in the system load 110a, 110b, 110c, 110d of the building 104 in real time.

[0126] The HX card 222 calculates the optimal flow and temperatures on the source side to achieve the most energy efficient system operation. The source side fluid flow can be controlled by various methods of heat transfer loop control.

[0127] The heat transfer system 300, 320 can monitor the amount of time the system operates at part loads and full loads (duty load) and, when the part load operating time exceeds a set time limit, can operate the control pumps 102a, 102b at full load flow to automatically flush the heat exchanger 118. Operating the pumps at full load flow activates the heat exchanger's 118 self-cleaning ability. This feature is programmed with parameters of cleaning frequency of self-cleaning hours per run time hours and time of day start for self-cleaning. An example default self-cleaning, full load flow operating timeis 30 minutes for every 168 hours (7 days) of part load operating time at 3am in the morning. The default part load threshold is set at 90% of full load flow (duty flow).

[0128] In some examples, the user has access to sensor readings on the HX card 222. Connected control pumps 102a, 102b can display real time sensor data on their . The HX card 222 uploads historic sensor data to the Cloud 308 where the user can access the sensor data.

[0129] In some examples, the HX card 222 can enable heat transfer algorithms (e.g., various heat transfer loop control), real time fouling tracking, and real time error monitoring and maintenance tracking.

[0130] The PC card 226 can communicatively connect to the HX card 222 and display, on the touch screen of the respective control pump 102a, 102b, additional trending, fouling tracking, and maintenance record information. The Cloud 308 can monitor the information and performance reports and error tracking to the customer with current usage, savings, and recommended actions.

[0131] The HX card 222 can store individual heat exchanger data, such as heat transfer module model and serial numbers, design points, mapped heat transfer performance curves (U value as a function of flow). Mapped data of heat transfer curves to be tested in house for each individual heat exchanger 118.

[0132] Service history can be stored on the Cloud 308. Service history can be upload to the HX card 222 through Webserver III, PC card 226, or Cloud 308. If the Cloud 308 does not have the most up to date version then the HX card 222 can push the records to the Cloud 308. If the Cloud 308 has the most up to date version, the Cloud 308 can push the record to the HX card 222.

[0133] For the HX card 222, in some examples, data sampling (inlet and outlet temperatures and pressure of hot and cold side, hot and cold side flow) can be taken every minute up to but not longer than every 5 minutes. Data can be regularly updated and stored on the Cloud 308. All inputs and calculated parameters can be updated as per the sampling time and can be shown on the display screen of the control pump 102a, 102b. The calculated parameters include, delta T, differential pressure, flow, lldirt (overall heat transfer coefficient of heat exchanger after some time of operation), and the heatexchanged (calculated for both the source and load side fluids), total pumping energy, and system efficiency (heat exchanged divided by the total pumping energy, shown in units of Btu / h in imperial and kW in metric).

[0134] Example various controls operations (flow control modes) of the heat transfer system 300, 320 are as follows. 1. Constant speed control. 2. Tsource, out control (Feed Forward Control Mode or Method). 3. Tload, out control (Feed Forward Control Mode). 4. Proportional Flow Matching. 5. Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. 6. Maximize Source Side Delta T with variable temperature approach and variable load side Delta T. Examples of the various control operations (flow control modes) are illustrated in, for example, PCT Application No. PCT / CA2019 / 051428 filed October 4, 2019, the entire contents of which are herein incorporated by reference.

[0135] In an example, the controllers 116 are configured to switch between one or more of these six types of flow control modes. In some examples, at least one of the control modes is a feed forward control. In some examples, at least one of the control modes is a feedback control. For example, the controllers 116 are configured to switch to, or from, one type of the flow control mode to or from a different second type of flow control mode.

[0136] In an example, the decision by the controllers 116 to switch to a different control mode is based on the sensed information from one or more of the sensors of the environment, for example as operating conditions change, or as parts of the system degrade or fail. In some cases, for example, when sensor information from one or more sensors is no longer available, the control mode is switched to a flow control mode of operation that does not require data from those one or more sensors. In some examples, the flow control mode that is selected by the controllers 116 is the flow control mode that best maintains constant load side temperature. In some examples, the flow control mode that is selected by the controllers 116 is the flow control mode that minimized energy consumed for the heat load transferred.

[0137] In other examples, the decision by the controllers 116 to switch control modes is rule based, such as time of day, particular season of the year, for maintenance, manual control, etc.

[0138] Figure 4A illustrates a graph 400 of an example heat load profile for a load such as for the load 110a, 110b, 110c, 110d of the building 104 (Figure 1 B), for example, for a projected or measured "design day". The load profile illustrates the operating hours percentage versus the heat load percentage (heat load refers to either heating load or cooling load). For example, as shown, many example systems may require operation at only 0% to 60% load capacity 90% of the time or more. In some examples, a control pump 102a may be selected for best efficiency operation at partial load, for example on or about 50% of peak load. Note that, ASHRAE (RTM) 90.1 standard for energy savings requires control of devices that will result in pump motor demand of no more than 30% of design wattage at 50% of design water flow (e.g. 70% energy savings at 50% of peak load). The heat load can be measured in BTU / hr (or kW). It is understand that the "design day" may not be limited to 24 hours, but can be determined for shorter or long system periods, such as one month, one year, or multiple years.

[0139] Figure 4B illustrates a graphical user interface 410 for configuring the load profile of Figure 4A, in accordance with an example embodiment.

[0140] Figure 4C illustrates a graph 420 of an example flow load profile for the load 110a, 110b, 110c, 110d of the building 104 (Figure 1 B), for a projected or measured “design day”. The load 110a, 110b, 110c, 110d of the building 104 (Figure 1 B) defines pumping energy consumption. Example embodiment relate to optimizing the selection of the heat exchanger 118, the control pump 102a, 102b, and other devices of the building system 100, when the building 104 operates most of the time below 50% flow of duty capacity (100%).

[0141] Figure 4D illustrates a graphical user interface 440 for configuring the load profile 420 of Figure 4C, in accordance with an example embodiment. The load profile 420 includes load data with associated time data (in this example, load percentage with associated time percentage). The graphical user interface screen allows the user to be provided with model numbers of the components of the entire heat transfer system, by specified parameters specific to the control pump 102a, 102b and the heat exchanger 118. Features include having the options to select the application (heating, cooling, or both), building type, location, climate location, and zone type which can be used to define a building operating profile. The particular time percentage versus flow percentage canbe modelled based on the initial input options, and manually adjusted though the graphical user interface 440 through design or real-time measurement.

[0142] The graphical user interface 440 and generating of the load profiles of the building system 100 can estimate the pump operating energy cost of each specific pump model of the control pump 102a, 102b, selected based on the unique capacity, based on the pump operating hours, building type, geographical location, application and the building’s cost per kWh. This graphical user interface 440 reduces or removes presumptions on any of the equipment and components that have already been imbedded such as what the building’s operating load profile would be what how that reflects in the overall pump operating costs. Previous over all data and models is used for generating the load profiles, for example using data from various and several different pump applications offered globally. In examples, the background data and the graphical user interface 440 can be constantly evolving and updated to ensure the most accurate results are provided.

[0143] The control pumps 102a, 102b can be selected and controlled so that the control pumps 102a, 102b are optimized for partial load rather than 100% load. For example, the control pumps 102a, 102b can have the respective variably controllable motor be controlled along a “control curve” of head versus flow, so that operation has maximized energy efficiency during part load operation (e.g. 50%) of the particular building system 100, such as in the case of the load profile graph 400 (Figure 4A) or load profile graph 420 (Figure 4B). Other example control curves may use different parameters or variables.

[0144] In an example, the controller 116 or another device determines or adjusts the load profile graph 420 based on real-time operation of the building 104 and / or using a testing jig or testing rig.

[0145] Referring again to Figure 1A, the pump device 106a may take on various forms of pumps which have variable speed control. In some example embodiments, the pump device 106a includes at least a sealed casing which houses the pump device 106a, which at least defines an input element for receiving a circulation medium and an output element for outputting the circulation medium. The pump device 106a includes one or more operable elements, including a variable motor which can be variably controlled fromthe control device 108a to rotate at variable speeds. The pump device 106a also includes an impeller which is operably coupled to the motor and spins based on the speed of the motor, to circulate the circulation medium. The pump device 106a may further include additional suitable operable elements or features, depending on the type of pump device 106a. Some device properties of the pump device 106a, such as the motor speed and power, may be self-detected by an internal sensor of the control device 108a.

[0146] Referring again to Figure 1A, the control device 108a, 108b for each control pump 102a, 102b may include an internal detector or sensor, typically referred to in the art as a “sensorless” control pump because an external sensor is not required. The internal detector may be configured to self-detect, for example, device properties such as the power and speed of the pump device 106a. Other input variables may be detected. The pump speed of the pump device 106a, 106b may be varied to achieve a pressure and flow setpoint, or a temperature and heat load setpoint, of the pump device 106a in dependence of the internal detector. A program map may be used by the control device 108a, 108b to map a detected power and speed to resultant output properties, such as head output and flow output, or temperature output and heat load output.

[0147] The relationship between parameters may be approximated by particular affinity laws, which may be affected by volume, pressure, and Brake Horsepower (BHP) (hp I kW). For example, for variations in impeller diameter, at constant speed: D1 / D2 = Q1 / Q2; H1 / H2 = D12 / D22; BHP1 / BHP2 = D13 / D23. For example, for variations in speed, with constant impeller diameter: S1 / S2 = Q1 / Q2; H1 / H2 = S12 / S22; BHP1 / BHP2 = S13 / S23. Wherein: D = Impeller Diameter (Ins I mm); H = Pump Head (Ft / m); Q = Pump Capacity (gpm I Ips); S = Speed (rpm I rps); BHP = Brake Horsepower (Shaft Power - hp / kW).

[0148] Variations may be made in example embodiments. Some example embodiments may be applied to any variable speed device, and not limited to variable speed control pumps. For example, some additional embodiments may use different parameters or variables, and may use more than two parameters (e.g. three parameters on a three dimensional map, or N parameters on a N-dimensional map). Some example embodiments may be applied to any devices which are dependent on two or more correlated parameters. Some example embodiments can include variables dependent onparameters or variables such as liquid, temperature, viscosity, suction pressure, site elevation and number of devices or pump operating.

[0149] Figure 5 illustrates a flow diagram of an example method 500 for facilitation selection of equipment for operation in the building system 100 (e.g., the building 104), in accordance with an example embodiment. At least some of the method 500 can be performed by a processor (e.g. processor 1220 and / or controller 1206 as in Figure 12). The processor can generate for display a graphical user interface for selecting of components of the building system 100. At step 502, the processor can receive a design setpoint of the building system 100 (e.g., the building 104). The design setpoint can be manually received (designed) or can be measured using existing equipment already operating in the building system 100. At step 504, the processor can receive the load profile of the building system 100 (e.g., the building 104). In examples, the load profile can be a heat load profile or a flow load profile. The load profile can be manually received (designed) as in Figures 4A-4D, or can be measured using existing equipment already operating in the building system 100.

[0150] At step 506, one or more specific models of equipment (components) of the building system 100 are generated and output to a display screen (or generating a suitable a document) as suitable suggestions for installation in the building 104. The prioritized combination is generated based on the design setpoint at step 502 and the load profile at step 504. The suggestions of the components can include: the load side control pump 102a, the source side control pump 102b, and the heat exchanger 118 (or the heat transfer module 220, 230). In an example, the output (or document) can includes the prioritized equipment combinations, cost (and cost savings), and sales quotation can also be generated and output. In an example, only one combination of equipment is generated and output as the recommendation combination, which can also include costs and comparisons, which is the sole recommendation combination and has the highest priority (or score) of the calculated combinations. A comparison can be generated that shows the performance of the recommended calculation versus a baseline calculation. At step 508, the processor receives selection of the desired model of the load side control pump 102a, the source side control pump 102b, the air separator 132, and the heatexchanger 118 (or the heat transfer module 220, 230), for installing and operating these equipment within the building system 100.

[0151] Ordering, billing, delivery, and installation of the selected equipment can be performed per the selection at step 508. After installation and real-time operation, the processor (or controller 116) can measure and learn from the actual costs of operating the selected combination of equipment versus predicted costs, for example for model refinement and updating to provide more accurate priority and cost estimates.

[0152] In examples, the method 500 includes the processor generating output for configuring at least one of the control pumps 102a, 102b (or one or more candidate variable flow control mechanical devices) of the one of the combinations that is selected with the respective control curve having the respective setpoint which includes the differential capability from the design setpoint. In examples, the output includes program instructions for programming at least one of the control pump 102a, 102b with such updated setpoint and a quadratic control curve from the updated setpoint. In examples, the output includes a message or a graphical interface output. Similarly, the method 500 can include the processor generating output for configuring the relevant respective updated setpoint of the other equipment, such as the heat exchanger 118 (or the heat transfer module 220, 230) and the air separator 132.

[0153] Figure 7A illustrates a graph 700 of an example range of operation and selection range (design point region 740) of a variable speed control pump 102a, 102b for a building system 100. The following relates to control pump 102a, and a similar process can be applied to control pump 102b. Efficiency curves (in percentage) are shown that bottom left to top right, and have a peak efficiency curve of 78% in this example. Power efficiency can relate to carbon and greenhouse emission, for example.

[0154] The range of operation 702 is illustrated as a polygon-shaped region or area on the graph 700, wherein the region is bounded by a border represents a suitable range of operation 702. A design point region 740 is within the range of operation 702 and includes a border which represents the suitable range of selection of a design point for a particular control pump 102a, 102b, e.g. point A (710) in this example. The design point region 740 may be referred to as a "selection range", "composite curve" or "design envelope" for a particular control pump 102a, 102b. In some example embodiments, thedesign point region 740 may be used to select an appropriate model or type of control pump 102a, 102b, which is optimized for part load operation based on a particular design point. For example, a design point may be, e.g., a maximum expected system load as in the full load duty flow illustrated by point A (710) as required by a system such as the building 104 (Figure 1 B). By way of a graphical user interface, a user can select (e.g. click) a design point of the building 104 on the graph 700, and any control pump 102a that overlaps with the design point region 740 is output to the graphical user interface, as those control pumps are considered to be suitable candidates for that particular design point of the building 104.

[0155] The design point can be estimated by the system designer based on the maximum flow (duty flow) that will be required by the building system 100 for effective operation and the head I pressure loss required to pump the design flow through the system piping and fittings. Note that, as pump head estimates may be over-estimated, most systems will never reach the design pressure and will exceed the design flow and power. Other systems, where designers have under-estimated the required head, will operate at a higher pressure than the design point. For such a circumstance, one feature of properly selecting an intelligent variable speed control pump is that the variable speed control pump can be properly adjusted to delivery more flow and head in the system than the designer specified.

[0156] The graph 700 includes axes which include parameters which are correlated. For example, head squared is proportional to flow, and flow is proportional to speed. In the example shown, the abscissa or x-axis 704 illustrates flow in U.S. gallons per minute (GPM) (alternatively litres / m inute) and the ordinate or y-axis 706 illustrates head (H) in feet (alternatively in pounds per square inch (psi) or metres). The range of operation 702 is a superimposed representation of the control pump 102a, 102b with respect to those parameters, onto the graph 700.

[0157] As shown in Figure 7A, one or more control curves 708 (one shown) may be defined and programmed for an intelligent variable speed device, such as the control pump 102a, 102b. Depending on changes to the detected parameters (e.g. external or internal detection of changes in flow / load), the operation of the control pump 102a, 102b may be maintained to operate on the same control curve 708 based on instructions fromthe control device 108a, 108b (e.g. at a higher or lower flow point). This mode of control may also be referred to as quadratic pressure control (QPC), as the control curve 708 is a quadratic curve between two operating points (e.g., point A (710): maximum head, and point C (714): minimum head which can be calculated as 40% of maximum head). Reference to "intelligent" devices herein includes the control pump 102a, 102b being able to self-adjust operation of the control pump 102a, 102b along the control curve 708, depending on the particular required or detected load. A thicker region on the control curve 708 represents the average load when operating to source the building 104.

[0158] The design point region 740 can be optimized for selection of an appropriate control pump 102a, 102b through a graphical user interface, that takes into account the heat exchanger 118 in the system 100. In view of Figure 7A, an example embodiment is a method performed by the controllers 116 for selecting a variable speed device, such as one or both control pumps 102a, 102b, from a plurality of such variable speed devices, the variable speed device having a variably controllable motor in order to source system load. Control curve information of the variable speed device is dependent on at least a first parameter (e.g. head) and a second parameter (e.g. flow), the first parameter and the second parameter being correlated. The method can include generating for display a graphical user interface to a display screen. The method includes: determining a design point of rated total value of the system load for the first parameter and rated total value of the system load for the second parameter; determining that an additional capability (or capacity) of the rated total value of the first parameter or the second parameter is required to account for changes in system resistance of the system load caused by the heat exchanger 118; and outputting (e.g., sending or displaying) one or more of the variable speed devices which minimally satisfies the additional capacity (capability) required to source the system load taking into account the heat exchanger 118. The method can include selecting, or receiving selection of, one of the variable speed devices through the graphical user interface. The method can include installing and operating the selected variable speed device (control pump 102a, 102b) in the building system 100. References to “capability” can similarly apply to “capacity” in any and all examples described herein.

[0159] In an example, the selected control pump 102a, 102b can operate at an increased head, or at maximum head allowable. The quadratic pressure control (QPC) can use this increased head value as the new setpoint (e.g. , point A (710)) for the control pump 102a, 102b, using the QPC and control curve 708 calculation noted above. In such an example, the increased pressure can be used to account for installing or replacing other equipment in the building system 100 to have a higher pressure drop compared to a base case or the existing installed equipment, such as the heat exchanger 118 or the air separator 132.

[0160] In some examples, the additional capability or capacity includes a power capacity that is available from the candidate device such as a variable speed device (e.g. control pump 102a, 102b) in order to account for the increased pressure caused by the heat exchanger 118. The determining of the design point can include receiving the design point through the graphical user interface. In some examples, the additional capacity includes a heat transfer capacity, a pressure or head capacity, a heat load capacity, and / or a flow capacity.

[0161] Maximum head is one example. Another example for the setpoint include selecting of two (or more) parallel pumps that achieve the setpoint, which includes dividing maximum head into half or other suitable apportionments (e.g. equally or unequally). In other examples, other design points for suitable selection of the control pump are used that are not the maximum head, such as best efficient point (BEP) or BEP curve of the control pump 102a, 102b. In other examples, other ranges for suitable selection of the control pump are used that are within the range of operation of the control pump.

[0162] Figure 7B illustrates a graph 750 of an example range of operation and selection range of a variable speed control pump 102a, 102b for the building system 100, having an operating point: flow of 500 gpm (3.78 Ipm) and head of 115 ft (35 m). Figure 7C illustrates a graph 760 of the variable speed control pump 102a, 102b of Figure 7B, having an operating point: flow of 500 gpm (3.78 Ipm) and head of 131 ft (40 m) (maximum head). In Figure 7C, the increased setpoint of head for the variable speed control pump 102a, 102b can be used to increase the pressure drop on the heat exchanger 118 without changing the control pump 102a, 102b, and therefore the pumpcapital cost expenditures. Further, or in the alternative, the increased setpoint of head can be used to increase the pressure drop on other equipment in the building system 100, such as the air separator 132. The particular combination of equipment can be optimized collectively to optimize cost, for example using an iterative algorithm.

[0163] Reference is now made to Figures 8A, 8B and 8C, which illustrate different design envelopes (selection ranges) for selecting of a candidate heat exchanger 118 for installation in the system 100 from a plurality of models of heat exchangers. Figures 8A, 8B and 8C illustrate interactive graphical user interface that include a respective graph where a user can select (e.g. click) the design point (e.g. duty load) of the building system 100. The particular heat exchanger 118 that overlaps with the design point is a candidate for installation in the building system 100.

[0164] Figure 8A illustrates a graph 800 of system head versus flow, having selection ranges for selecting of one or more candidate heat exchangers 118 for the building system 100. In Figure 8A, there are four heat exchangers HX1 , HX2, HX3, HX4 that may be selected. Figure 8B illustrates a graph 820 of cooling capacity versus flow, having selection ranges for selecting of one or more candidate heat exchangers 118 for the building system 100. In Figure 8B, there are two heat exchangers HX3, HX4 that may be selected in the illustrated range. Figure 8C illustrates a graph 840 of heating capacity versus flow, having selection ranges for selecting of one or more candidate heat exchangers 118 for the building system 100. In Figure 8C, there are two heat exchangers HX3, HX4 that may be selected in the illustrated range.

[0165] For example, in Figure 8A, a user (or a processor) may select on the graph 800 the design point of 35 psi (24.6 m) and 300 US GPM (1136 liters I minute). In such an instance, all of the four heat exchangers HX1 , HX2, HX3 and HX4 may be output by the processor as being a candidate device for installation and operation in the building system 100. If a user selects on the graph 800 the design point of 35 psi (24.6 m) and 1700 US GPM (6435 liters I minute), then only heat exchanger HX4 is output by the processor as being a candidate device for installation and operation in the building system 100. In some examples, the user can then select one of the candidate heat exchangers 118 for installation and operation in the building system 100.

[0166] Similarly, when the known design point of the building system 100 is cooling capacity, then the graph 820 of Figure 8B can be used to select the candidate heat exchanger. When the known design point of the building system 100 is heating capacity, then the graph 840 of Figure 8C can be used to select the candidate device.

[0167] In some examples, once one or more candidate control pumps 102a, 102b and heat exchangers 118 are determined by the processor, the total cost of selecting, installing and operating these and other components of the building system 100 can be optimized using at least one processor.

[0168] Various examples of the air separator 132 may be used in example embodiments. For example, Figure 11A illustrates an air separator 132a that is a coalescing style air and dirt separator (DAS). Figure 11 B illustrates an air separator 132b that is a vortex style air separator. Other examples can include other types of air separator 132, such as degassers.

[0169] Figure 11A illustrates an air separator 132a that is a coalescing style air and dirt separator (DAS), for selection and operation in the building system 100. The air separator 132a includes a casing 1102, an inlet flange 1104, an outlet flange 1106, coalescing tubes 1108, a non-turbulent zone 1110, an air vent 1112 and a dirt chamber 1114.

[0170] In an example, the coalescing tubes 1108 are perforated. In an example, the coalescing tubes 1108 can be stainless steel tubes. In an example, the hole size of the perforations in the coalescing tubes 1108 affects the pressure drop and particle size that is filtered, and therefore the hole size is another variable that can be optimized.

[0171] The air separator 132a as a coalescing style air and dirt separator works by slowing the movement of circulation fluid through a large cross-section of the casing 1102. The coalescing tubes 1108 allow the slow-moving micro bubbles to cling to the coalescing tubes 1108 and coalesce, or join together. The bubbles then rise to the top of the air separator 132a, where they are vented through the air vent 1112, which can be an automatic air vent. In addition, dirt particles are directed down through the non-turbulent zone 1110 and stored in the dirt chamber 1114 at the bottom of the air separator 132a,where the dirt particles can be removed periodically. On low-load days, where the flow velocity is low, the performance of the coalescing-style air and dirt separator is improved.

[0172] The amount of dissolved air in a solution is dependent on several factors, but is governed mainly by fluid flow (velocity), temperature and pressure. In examples, the removal of air should be accomplished at a point in the building system 100 where pressure is lowest, and temperature is the highest. Many designers will utilize multiple air separators 132a located at the riser tops of heating systems or return risers on chilled water systems. Because pressure plays a predominant role in system site design, whole system elimination is often preferred where air elimination devices are located at (or near) the system pump suction. In these systems the system expansion tank must be hydraulically located at the pump suction to ensure optimum hydraulic stability and air elimination.

[0173] As air is eliminated at the pump suction of a control pump 102a, 102b, the fluid has reduced the dissolved air content in the fluid flow. As the pressure increases at the pump discharge, the fluid has an increased capability to absorb free air bubbles or air pockets. When the fluid contacts these free-air cavities, the fluid will absorb the air into solution (up to its saturation capacity), and carry the dissolved air back to the pump suction. At this point, the dissolved air will come back out of solution, where the air separator 132a separates and removes the air automatically from a hydronic system such as the building system 100. This operation will result in continually "scavenging" air from the hydronic system, removing potentially harmful air pockets and entrained air.

[0174] System debris (dirt) is a part of any hydronic system such as the building system 100 regardless of the care and diligence of the designer and contractor. Dirt can be found in the form of pipe thread shavings, metal scale, welding debris, rust particles, etc. Even chemical treatment used in many hydronic systems often leads to buildup of chemically altered debris flowing with the system fluid. Regardless of origin this debris settles on surfaces resulting in reduced heat transfer, reduction in pump seal life, plugged control and balancing valves, plus a host of other numerous system issues.

[0175] The air separator 132a can include a stainless steel perforated media in the coalescing tubes 1108 that filters the fluid flow with each pump cycle. The ability to remove dirt is heavily reliant on system design pump flow rates and particle size. The airseparator 132a works by allowing system fluid to flow into the air separator 132a and filtering out the dirt.

[0176] Figure 11 B illustrates an air separator 132b that is a vortex style air separator, for selection and operation in the building system 100. The air separator 132b includes a casing 1120, an inlet flange 1122, an outlet flange 1124, a screen 1126, and an air vent 1130. A water vortex 1128 is created for flowing water due to the shape and dimensions of the casing 1120.

[0177] Water enters though the inlet flange 112. The orientation, shape and dimensions of the casing 1120 promote a low velocity swirling effect in the center of the casing 1120. Centrifugal force moves the water to the outer edges of the unit and a vortex is formed. Entrained air migrates to the eye of the vortex (lower pressure point) and is evacuated at the top of the air separator 132b . The water exits the air separator 132b at the outlet flange 1124 near the bottom of the air separator 132b, bubble free, protecting the building system 110 against the noise, corrosion and damage associated with entrained air. The air separator 132b can include a manual drain.

[0178] In some examples, the vortex style air separator would not have a suitable selection range if the flow load profile of the building system 100 is low (e.g., below a flow threshold, and / or the low flow occurring above a time period threshold), and therefore the vortex style air separator would not be selected by the processor as a suitable or priority candidate in such circumstances.

[0179] Figure 11 C illustrates a graph of an example range of operation 1150 and selection range of the air separator 132a of Figure 11A, which is a coalescing style air and dirt separator. A similar graph, not shown, can be used for the air separator 132b that is a vortex style air separator, as in Figure 11 B The graph and example range of operation 1150 illustrates pressure drop versus flow rate. The air separator 132a has a range for selecting of one or more candidate air separators 132 for the building system 100, such as in the outlined parallelogram shaped box 1152. For example, in Figure 11 C, a user (or processor) may select on the graph the design point of a desired air separator 132, and the particular air separator 132a is considered to be a candidate when overlapped with the box 1152, and that air separator 132a is output and / or part of a combination of candidate equipment for the building system 100.

[0180] As can be seen in the range of operation 1150 of the air separator 132a, the pressure drop is dependent on flow rate. The parameter “fps” stands for foot-pound- second (alternatively meter, kilogram and second (MKS)). For example, the building flow load profile affects the amount of pressure drop. The particular duration of the pressure drop can be calculated from the design day of the building system 100. The maximum flow in the building system 100 affects the maximum pressure drop. The calculation of the design point of a candidate control pump 102a, 102b can take into account the pressure drop due to the air separator 132a.

[0181] Other performance parameters of the capability (or capacity) of the air separator 132a can be used for the method by the processor, such as the ability of the particular air separator 132a to remove fouling and / or the ability to remove air, therefore affecting performance and cost within the rest of the system building 100. Another capability (or capacity) the particular air separator 132a is the removal efficiency in response to the received flow and / or pressure.

[0182] Reference is now made to Figures 9A and 9B. The determining of the candidate model of control pumps 102a, 102b, heat exchangers 118, and / or air separator 132 can be performed, using one or more processors, through the respective graphical user interface screens 900, 920 shown in Figures 9A and 9B, respectively. In some examples, the one or more processors can provide a specific recommendation of the best combination (or a priority list) of control pumps 102a, 102b and heat exchanger 118 for a particular building system 100. In examples, the fields in Figures 9A and 9B can include a manual insertion field or a drop-down selectable field, as shown. In examples, other equipment such as the air separator 132 is also part of the recommendation combination or priority list.

[0183] Referring to the graphical user interface screen 900 in Figure 9A, a Preselect screen allows the user to be provided with model numbers of the components of the entire heat transfer system, by specified parameters specific to the control pump 102a, 102b and the heat exchanger 118. The default units are shown in the graphical user interface screen 900. One feature is having the options to select the building type and location, which defines a building operating profile. This profile allows the processors to optimize the combination selection of the heat exchanger 118, control pump 102a,102b, and / or the air separator 132. The load profile can be defined for different building types and shifted per ASHRAE (RTM) procedures for different locations.

[0184] In some examples, the pump and heat exchanger redundancy allowed is selectable and can be 0% or from 50% to 100%.

[0185] In some examples, the fluid can be selected from water and water-glycol mixture. If the user hovers their mouse over the “System head without the heat exchanger” a comment will pop up with further explanation.

[0186] Referring to the graphical user interface screen 920 in Figure 9B, the load profile box allows the user to change the load profile as per their requirement. The discount period and discount rate can also be customized for each project. The user can also simulate different operating scenarios required with the rating option.

[0187] In examples, the load profile can be configured using the respective graphical user interface of Figure 4B or Figure 4D.

[0188] Once the graphical user screens 900, 920 are completed, the total cost of selecting, installing and operating the control pumps 102a, 102b, the heat exchanger 118, and other equipment (components) of the building system 100 such as the air separator 132 can be optimized. A particular model of the control pumps 102a, 102b, the heat exchanger 118, and the air separator 132 which has the optimal cost can be recommended by the one or more processors as a combination, or in other examples, a priority list of different combination options.

[0189] The total costs of the building system 100 are comprised of the first installed costs and operating costs. First installed costs comprised of the heat exchanger 118, control pumps 102a, 102b, air separator 132, valves, pressure independent control valves (PICVs), suction guides, piping (including any headers), and installation costs. Operation costs are comprised of pumping energy. The total cost is compared to other selections using the net present value method based on the user defined discount years and discount rate (e.g. interest rate). In examples, the number of years for payback can be set through the user interface. The default number of years can be, e.g., 1 year and the default discount rate is, e.g., 5%. Othe example years is 3 years, and 5 years, and 10 years.

[0190] The pressure drop across the heat exchanger 118 is varied in 0.5 psi increments and the lifecycle cost is obtained and stored in memory for each scenario. Equipment is then ranked based on the lowest lifecycle costs. A combination of equipment for the building system 100 can be generated and output by the one or more processors.

[0191] The net present value (NPV) is calculated as:Where:Rt is the cost at a specific year t,N is the number of years, i is the discount rate (e.g. interest rate), t is the specific year.

[0192] The building load profile are selected, using one or more processors, based on the user application and location, for example. The number of years for the NPV can be set through the user interface. In an example, the NPV is optimized so as to minimize cost of the combination of equipment for the building system 100 over a selected time period, such as one year, three years, etc. The building load profile can be taken from the parallel redundancy specifications. The building load profile can be taken from the load profile graph 400 (Figure 4A) or the load profile graph 420 (Figure 4C). The total pumping energy is calculated by integrating the pump energy with the chosen load profile.

[0193] Figure 10A illustrates a graphical user interface 1000 for generating (calculating) and outputting options of control pumps 102a, 102b and heat exchangers 118 for the building system 100. In other examples, other equipment such as the air separator 132 is considered in terms of pressure drop and performance in order to provide a cost and cost savings calculation. Figure 10B illustrates a graphical user interface 1020 for outputting proposed equipment from the options for the building system 100. Figure 10C illustrates a graphical user interface 1040 for outputting a proposal letterof the proposed equipment of Figure 10B. In examples, the generating of the data and the generating of the graphical user interfaces are performed by a processor (e.g. processor 1220 and / or controller 1206 as in Figure 12).

[0194] Reference is made to the graphical user interface 1000 of Figure 10A. In examples, the processor takes into account the interrelated effects of various equipment on the building system 100. For example, considering both control pumps 102a, 102b running on both sides of the heat exchanger 118 (hot and cold fluids) as well as the heat exchanger 118, the processor iterates between the different heads that the control pumps 102a, 102b can offer and how those can affect the heat exchanger pressure drop. The processor then computes between all of the different combinations of control pumps 102a, 102b and heat exchanger 118, their capital costs and operating energy costs over a pump lifetime, and provides the graphical user interface 1000 (e.g. user such as a design engineer, mechanical contractor etc.) with a shortlisted or prioritized selection of control pumps 102a, 102b and heat exchanger 118 based on both capital and operational cost savings compared to the traditional base case selection. In some examples, the optimal combination is output to the graphical user interface 1000. In some examples, other equipment such as the air separator 132 can also be optimized and iterated as a combination with, for example, at least one of the control pumps 102a, 102b and / or with the heat exchanger 118, in a similar manner.

[0195] In an example, the processor is configured to maximize the pressure drop on the heat exchanger 118. For example, the 118 takes the selected base case operating capacity for each candidate control pump 102a, 102b selected and then iterates the different heads on the control pump 102a, 102b can operate at. The processor then converts each of those iterations into the equivalent increased (or in some occasions, decreased) pressure drop for the heat exchanger 118 and how the pressure drop changes the overall size of the heat exchanger 118 (e.g. model, plate configuration design and size). The iteration also allows for automatic unit conversion between the pump head (i.e. unit selected in ft, alternatively metres) to the heat exchanger pressure drop (i.e. unit selected in psi, alternatively kPa).

[0196] For each iteration completed, the processor logs the pump model, capital cost and operating energy cost for the payback period (e.g. 1 year, or can be input ordynamically adjusted) for the candidate control pump 102a, 102b and for the heat exchanger 118, the processor logs the model and capital cost. The calculation allows for the different iterations to be completed automatically between different control pumps 102a, 102b and heat exchangers 118. The processor then generates for display, and displays through the graphical user interface 1000, the results in a tabulated grid and graph that allow the user to best visualize the different pump and heat exchanger options, their capital expenditure and overall lifetime operating costs.

[0197] In an example, as shown in Figure 10A, several candidates of the combinations variable flow control mechanical devices and equipment can be processed. In examples, reference to parallel pump in the graphical user interface 1000 can be either two separate parallel control pumps 102a, 102b operating in parallel, or a dual control pump 102a, 102b in a manner as illustrated in Figure 2E. Reference to hot side and control side may be reversed depending on the particular application and the temperature source for the building system 100, and in some examples hot and cold can be reversed by reversing a temperature cycle or a heat pump. In an example, the heat exchanger is a Plate and Frame Heat Exchanger Pressure (PFX PD), which has an associated Pressure Drop (PFX PD).

[0198] In an example, the rows of the candidate control pump 102a, 102b represent options types and include, for the hot side control pump 102a, 102b: i) single pump: base case design capacity, ii) single pump: maximize pump head available and add difference to PFX PD, iii) single pump: upsize pump and maximize head available, then add to PFX PD, iv) parallel pump: base case design capacity but with 2 or more pumps running in parallel in order to utilize best efficiencies, and v) parallel pump: maximize pump head available and add difference to PFX PD. In an example, the rows of the candidate control pump 102a, 102b represent options types and include, for the cold side control pump 102a, 102b: i) single pump base case design capacity, ii) single pump: maximize pump head available and add difference to PFX PD, iii) single pump: upsize pump and maximize head available, then add to PFX PD, iv) parallel pump: base case design capacity but with 2 or more pumps running in parallel in order to utilize best efficiencies, and v) parallel pump: maximize pump head available and difference to PFX PD. The columns for the candidate control pump 102a, 102b include: Number of totalpump and heat exchanger sets the user is computing in one project, selection tool formatting (compact: only shows required fields, detailed: shows all available fields), currency, multiplier (for sales team), pump tag (per schedule to ensure differentiation from other pumps in the project), total number of pumps for this application that are required per project schedule, total number of pumps in parallel, pump flow (multiple measurement units are available both in SI and imperial), pump head (multiple measurements units are available both in SI and imperial), Pump Model selected, price associated with pump model selected and annual energy cost associated with pump model selected.

[0199] In an example, the rows of the candidate heat exchanger 118 represent options types and include: i) single pump: base case design capacity, ii) single pump: maximize pump head available and add difference to PFX PD, iii) single pump: upsize pump and maximize head available, then add to PFX PD, iv) parallel pumps: base case design capacity but with 2 or more pumps running in parallel in order to utilize best efficiencies, v) parallel pumps: maximize pump head available and add difference to PFX PD, and vi) mixed pumps (uses PD allowable from pump with lowest capital cost and allocates the respective PD of PFX resulting in a unique option that can utilize both single pumps and parallel pumps for the PFX unit based on lower capital expenditure. The columns for the candidate heat exchanger 118 include: Number of total pump and heat exchanger sets the user is computing in one project, selection tool formatting (compact: only shows required fields, detailed: shows all available fields), currency, multiplier (for sales team), heat exchanger tag (per schedule to ensure differentiation from other heat exchangers in the project), total number of heat exchangers for this application that are required per project schedule, heat load (multiple measurement units are available both in SI and imperial), heat exchanger pressure drop for both hot and cold side of the heat exchanger (multiple units are available), Heat Exchanger Model selected, price associated with heat exchanger model.

[0200] Referring to Figure 10B and the graphical user interface 1020, based on the different iterations completed by the processor, the processor provides the user with a clear option for both control pumps 102a, 102b and heat exchanger 118 based on capital and operating costs along with savings compared to the base case, e.g. base case isdefined as the traditionally designed heat exchanger 118 and control pumps 102a, 102b for the building system 100 using the initial design point of the building system 100. In other examples, the base case is the equipment already installed in the building 104. Figure 10C illustrates a sales proposal letter for the recommended combination from Figure 10B, which can be generated for display through the graphical user interface 1040 or sent as a draft document for finalizing, and / or communicated in a message to a device of the end user. Further tabular and graphical representations of the data computations are displayed via the method and graphical user interface, allowing the user to visualize the all options available and better understand the finalized proposed alternative solution optimizing the heat exchanger with associated pumps selection.

[0201] In other examples, which may be less common scenarios where either the operating costs are exceeding all other driving factors or the pump capital cost is the driving factor, the method and graphical user interface can also be utilized in a reverse manner. This would mean that rather than increasing heat exchanger pressure by maximizing associated pump head, the heat exchanger pressure drop can be decreased by decreasing the pump head just enough to lower both the operating costs of the pump and the pump capital expenditure (e.g. smaller pump size, either in pump physical dimensions, motor size or both). In such examples, the differential capability considered for the candidate control pump versus the baseline control pump is a candidate control pump with lower capability. The candidate control pump can be set at a lower capability, e.g. a lower setpoint and associated control curve.

[0202] In examples, the processor is configured to generate output for configuring the control pump (or one or more candidate variable flow control mechanical devices) of the one of the combinations that is selected with the respective control curve having the respective setpoint which includes the differential capability from the design setpoint. In examples, the output includes program instructions for programming the control pump 102a, 102b with the new setpoint and a quadratic control curve from the new setpoint. In examples, the output includes a message or a graphical interface output. Similarly, the processor can be configured to generate output for configuring the setpoint of the equipment, such as the heat exchanger 118 (or the heat transfer module 220, 230) and the air separator 132.

[0203] Figure 12 illustrates an example block diagram of a communication system 1200 for facilitating selection of one or more equipment for operation in the building system 100, in accordance with an example embodiment. For example, the communication system 1200 may be used as a web portal for access by a client device 1202 to facilitate selection of a suitable control pump 102a, 102b, and other equipment such as the heat exchanger 118 and the air separator 132. As shown, a server system 1230 may communicate with one or more client devices 1202 (one shown) over a communications network 1204, such as the Internet. In examples, the client device 1202 is the smart device 304 and / or the BAS 302 (Figure 3A, Figure 3B).

[0204] The server system 1230 may be configured as a web server which generates graphical user interface (GUI) screens for display on the client device 1202. As shown in Figure 12, in some example embodiments, the server system 1230 may include one or more processors 1220, at least a memory 1222 for storing of system software and databases for devices or items, and at least a communications subsystem 1224. The server system 1230 may include one or more servers (one shown for ease of illustration).

[0205] The memory 1222 of the server system 1230 may include user information, which can include user information along with associated access rights. For example, a contractor / installer or sales representative may have read-only rights and some restricted access, while employees may have editing rights and / or further access rights. The memory 1222 may also include a database of a plurality of devices such as control pumps 102a, 102b, along with respective model numbers and ranges of operation 702, and design point regions 740 (see Figure 7a). The memory 1222 may also include a database of other equipment such as the heat exchanger 118 and the air separator 132, and their respective performance and / or selection regions.

[0206] The client device 1202 may include one or more client applications 1210. In some example embodiments, the client device 1202 may include a controller 1206 such as a microprocessor, which controls the overall operation of the client device 1202. The controller 1206 interacts with other device components such as memory 1208, and system software 1212 stored in the memory 1208 for executing the client applications 1210, input / output subsystems 1214 (e.g. a keyboard, mouse, touchpad, scrollwheel,and / or a display) and a communications subsystem 1216. A power source 1218 powers the client device 1202.

[0207] Referring still to Figure 12, in some example embodiments, the client device 1202 may be configured with a web browser which is used to access a web site or web portal of the server system 1230, for example to select a suitable control pump 102a, 102b and other equipment. The web browser is configured to render the graphical user interface screens onto the display of the client device 1202, based on information received from the server system 1230 or from resident information. The client device 1202 may, for example, be a tablet computer, a mobile phone, or general purpose device such as a personal computer. Some example embodiments may include the use of a dedicated installed application or"app" on the client device 1202. Some example embodiments may include a Virtual Private Network (VPN) or other credential-based access.

[0208] In some conventional selection systems, devices may already be categorized into predetermined or hard-coded groups, so that all of the devices in a group are retrieved depending on the desired search parameters (e.g. all devices from a particular family or group of models). The predetermined groups may not provide suitable results to the user, as too many results may be displayed. This can provide excessive results and limits flexibility of displaying results for subsequent selection by a user. Also, the user may not be aware of which devices would be most appropriate, which may result in less than optimal selection of an inappropriate or inefficient device for the desired end use or design point, or a combination of such devices and equipment.

[0209] Figure 6 illustrates an example flow diagram of a method 600 for prioritizing and selecting equipment for operation in the building system 100 having a variable load. The method can be performed by a processor, e.g. processor 1220 and / or controller 1206 as in Figure 12. In examples, NP is Net Price (e.g., initial cost or list price), OC is Operating Cost, and C is Cost (NP, OC).

[0210] At step 602, the net price per category is sorted for each equipment. The net price can be optionally sorted from lowest to highest. The categories of equipment can include control pumps, control valves, heat exchangers, air separators, and otherequipment. In an example, in a parallel pump scenario, the combined cost of the two parallel candidate control pumps is considered for the sorting.

[0211] At step 604, the processor determines a load profile of the variable load for the building system 100.

[0212] At step 606, the processor determines a design setpoint (or design point) of the variable load.

[0213] At step 608, the processor determines a baseline variable flow control mechanical device such as a baseline control pump for the design setpoint, and a baseline equipment for the baseline control pump. In other examples, the baseline variable flow control mechanical device is a baseline variable valve.

[0214] At step 610, the processor determines one or more candidate control pumps which have additional capability (or capacity) beyond the design setpoint, e.g. a maximum setpoint that is higher than the design setpoint. In other examples, a setpoint of an increased additional capability for the candidate control pump that is not the maximum setpoint of the candidate control pump is used for the method 600 and calculations.

[0215] In other examples, the processor determines one or more candidate control pumps which have a differential capability (or capacity) that is subtracted from the design setpoint, e.g. a lower capability (or capacity).

[0216] In an example, the candidate control pumps can be two (or more) control pumps for operation in parallel.

[0217] In an example, the candidate control pumps can be two (or more) control pumps, for example first control pump 102a for the first circuit of the heat exchanger 118 and second control pump 102b for the second circuit of the heat exchanger.

[0218] At step 612, an iterative calculation begins starting with the first candidate control pump(i). The first candidate control pump can start with the baseline control pump at a differential capacity, e.g. an additional capability or maximum setpoint as a setpoint. In examples, the calculation uses the candidate control pump(i) with a control curve having a differential capability versus the baseline control pump, e.g. the maximum setpoint (maximum head). The increased capability can be used to fulfill the otherequipment, e.g. increased pressure differential by the candidate control pump can be used to fit a heat exchanger having a larger pressure differential.

[0219] Maximum head is one example. Another example include selecting of two (or more) parallel pumps, which includes dividing the setpoint (e.g. maximum head) into half or other suitable apportionments. In other examples, other ranges for suitable are used that are not the maximum head, such as best efficient point (BEP) or BEP curve of the candidate control pump.

[0220] In another example, the differential capacity is a lower capacity or lower setpoint. For example, rather than increasing heat exchanger pressure, the heat exchanger pressure drop can be decreased from the setpoint by decreasing the pump head just enough to lower both the operating costs of the pump and the pump capital net cost expenditure (e.g. smaller pump size, either in pump physical dimensions, motor size or both). In such examples, the differential capability considered for the candidate control pump versus the baseline control pump is a candidate control pump with lower capability (or capacity). The candidate control pump can be set at a lower capability, e.g. a lower setpoint and associated control curve.

[0221] At step 614, the processor determines one or more candidate equipment for each candidate control pump that can be fulfilled by the setpoint (additional capability) of that candidate control pump(i), and / or has a selection range for the particular load profile, and the increased capability such as pressure differential available by the candidate control pump(i) operating at the maximum setpoint. Certain equipment can be removed from being candidate equipment for other reasons, such as equipment supply availability, design considerations, other restrictions or parameters that are not the particular variable of the additional capability. In an example, low flow applications may rule out certain or all vortex style air separators as candidate equipment.

[0222] At step 616, for each candidate equipment(j) for that particular candidate control pump(i), the processor starts an iteration at equipment(j). At step 618, the processor calculates, for the combination of the candidate variable control pump(i) and the candidate equipment(j), the cost of the combination operating in the building system 100. The cost of the combination includes the net price and the cost of operating the combination together according to the load profile, and the candidate variable controlpump(i) having a control curve set to the maximum setpoint. The calculation for the operating cost is over a set time period or a payback period. At step 620, the next candidate equipment(j+1) is considered, and the cost of the combination of the candidate variable control pump(i) and the next candidate equipment(j+1 ) is considered. In an example, the next highest net price equipment is the next candidate equipment(j+1 ).

[0223] After all of the candidate equipment has the cost calculated for the candidate control pump(i), at step 622, the next candidate control pump(i+1 ) is considered by the processor. In an example, the next candidate control pump(i+1 ) has the next highest net price. In examples, the same steps 616, 618, 620 are iterated to calculate subsequent cost of the combinations in consideration of each of the candidate equipment.

[0224] At step 624, after all of the candidate control pumps have cost calculated with combinations of equipment, the processor generates a priority based on the respective cost of the combinations (i, j). The priority can be a ranking from least expensive to the most expensive cost of the combination (i, j). The priority can be a suggestion of the optimal cost combination. The priority can be include comparing the optimal cost combination to the combined cost of the baseline control pump and the baseline equipment. In examples, the processor can output the priority or recommendation to outputting the priority to a graphical user interface, a document, a message, or to a device.

[0225] In other examples, an additional candidate control pump is considered for the cost calculation, for example the first control pump 102a for the first circuit of the heat exchanger 118, and the second control pump 102b for the second circuit of the heat exchanger 118. For example, not shown here, for the iterative calculations, another layer of iterations for candidates of the second control pump 102b can be performed for each heat exchanger(j), for the entire combination of the cost of the candidate first control pump 102a, the candidate second control pump 102b, and the heat exchanger (j). Further layers of iterations can include third iterations, fourth iterations, and so on.

[0226] At step 626, the processor receives selection of a particular combination of one or more heat pumps and one or more equipment, which can be the combination withthe lowest cost or some other priority. The receiving can be performed through a graphical user interface. A sales order can be generated if applicable.

[0227] The selected combination of control pump and equipment are installed and operated in the building system 100, for example, the control pump is operating over a control curve with the maximum setpoint (e.g., head) or additional capacity as the setpoint, and which fills the capacity difference (e.g. pressure drop) through the selected equipment.

[0228] In other examples, an additional candidate control pump that is in parallel is considered for the cost calculation, for example two control pumps operating in parallel (e.g., duty standby mode or dual simultaneously controlled).

[0229] In other examples, not shown here, additional categories equipment can be considered such as the combined cost of the control pump, the heat exchanger, the air separator, and / or other equipment. In some examples, further iterations of cost calculations can be performed to calculate various cost combinations. For example, not shown here, for the iterative calculations, another layer of iterations for air separator (k) (not shown) can be performed for each heat exchanger (j). In other examples, at steps 614, 616, 618, 620, not shown, a candidate air separator (j) is considered as an alternative to a candidate heat exchanger (j). Further layers of iterations can include third iterations, fourth iterations, and so on.

[0230] In an example, the cost calculation includes a NPV.

[0231] In an example, not all combinations are considered for calculation purposes.

[0232] For example, if calculation of a next highest net price candidate heat pump or equipment does not result in a lower cost, the particular previous cost combination may be considered to be the optimal cost, having reached a local minima.

[0233] In an example, a model or a machine learning model is used for the calculation.

[0234] An example embodiment is a method for a system having a variable load, the variable load being representable by a first parameter and a second parameter thatare correlated, the method being performed by at least one processor and comprising: determining a load profile of the variable load; determining a design setpoint of the variable load; determining one or more candidate variable flow control mechanical devices which have a differential capability from the design setpoint, wherein the differential capability is a pressure variable; determining, for each of the one or more candidate variable flow control mechanical devices, one or more candidate equipment that are fulfilled by the differential capability; calculating a respective cost of combinations of the one or more candidate variable flow control mechanical devices and the one or more candidate equipment operating together according to the load profile and the one or more candidate variable flow control mechanical devices operating on a respective control curve having a respective setpoint which includes the differential capability from the design setpoint, including iteratively calculating by first iterating respective cost of the one or more candidate variable flow control mechanical devices, and second iterating, for the one or more candidate variable flow control mechanical devices from the first iterating, respective cost of the one or more candidate equipment; generating a priority based on the respective cost of the combinations; receiving selection of one of the combinations; and generating output for configuring the one or more candidate variable flow control mechanical devices of the one of the combinations that is selected with the respective control curve having the respective setpoint which includes the differential capability from the design setpoint.

[0235] In another example embodiment of the method of any of the above, the differential capability is an additional capability or additional capacity beyond the design setpoint.

[0236] In another example embodiment of the method of any of the above, the differential capability is a reduced capability or reduced capacity from the design setpoint.

[0237] In another example embodiment of the method of any of the above, the one or more candidate variable flow control mechanical devices comprise one or more candidate valves.

[0238] In another example embodiment of the method of any of the above, the one or more candidate variable flow control mechanical devices comprise one or more candidate variable control pumps.

[0239] In another example embodiment of the method of any of the above, the method further includes determining a baseline variable control pump having the design setpoint.

[0240] In another example embodiment of the method of any of the above, one of the candidate variable control pumps includes the baseline variable control pump operating at the differential capability from the design setpoint.

[0241] In another example embodiment of the method of any of the above, the generating the priority includes generating a comparison of respective cost of the baseline variable control pump operating on a control curve including the design setpoint to at least one other of the candidate variable control pumps.

[0242] In another example embodiment of the method of any of the above, the method further includes determining a baseline equipment for the baseline variable control pump, wherein the generating the priority includes generating a comparison of respective cost of the baseline equipment to at least one other of the candidate equipment.

[0243] In another example embodiment of the method of any of the above, the calculating the respective cost is for the one or more candidate variable control pumps taking to account respective operation on the control curve of the first parameter versus the second parameter, wherein the control curve includes the setpoint which includes the differential capability from the design setpoint.

[0244] In another example embodiment of the method of any of the above, the one or more candidate variable control pumps are sensorless control pumps that operate on the control curve using at least one self-detected device property without an external sensor.

[0245] In another example embodiment of the method of any of the above, the differential capability is a maximum respective capability of each of the one or more candidate variable control pumps.

[0246] In another example embodiment of the method of any of the above, the pressure variable is pressure capability, head capability, pressure capacity or head capacity.

[0247] In another example embodiment of the method of any of the above, the one or more candidate variable control pumps include at least two candidate control pumps for parallel operation.

[0248] In another example embodiment of the method of any of the above, the generating the priority includes recommending one of the combinations having an optimal cost.

[0249] In another example embodiment of the method of any of the above, the calculating of the respective cost of combinations is based on initial cost and operating cost over a payback period.

[0250] In another example embodiment of the method of any of the above, the iteratively calculating includes third iterating, for the one or more candidate equipment of the second iterating, respective further cost of further one or more of the candidate equipment which is in a different equipment category than the one or more candidate equipment of the second iterating.

[0251] In another example embodiment of the method of any of the above, the load profile includes load data with associated time data or load percentage with associated time percentage.

[0252] In another example embodiment of the method of any of the above, the first parameter is one of the pressure variable or flow, and the second parameter is the other of the pressure variable or the flow.

[0253] In another example embodiment of the method of any of the above, the design setpoint of the system is a maximum pressure at a maximum flow.

[0254] In another example embodiment of the method of any of the above, the one or more candidate equipment includes a heat exchanger that defines a first fluid circuit and a second fluid circuit.

[0255] In another example embodiment of the method of any of the above, the one or more candidate variable flow control mechanical devices include one or more first candidate variable flow control mechanical devices for the first fluid circuit and one ormore second candidate variable flow control mechanical devices for the second fluid circuit.

[0256] In another example embodiment of the method of any of the above, the one or more candidate equipment includes an air separator.

[0257] In another example embodiment of the method of any of the above, the one or more candidate equipment includes two or more candidate equipment, and the calculating the respective cost of the combinations is based on the two or more candidate equipment operating together with the one or more candidate variable flow control mechanical devices according to the load profile.

[0258] In another example embodiment of the method of any of the above, the control curve is a quadratic control curve.

[0259] In another example embodiment of the method of any of the above, the output includes program instructions for the configuring the one or more candidate variable flow control mechanical devices of the one of the combinations that is selected.

[0260] Another example embodiment is a method for a system having a variable load, the method being performed by at least one processor and comprising: determining a load profile of the variable load; determining a design setpoint of the variable load; determining one or more candidate variable flow control mechanical devices which have a differential capability from the design setpoint, wherein the differential capability is a pressure variable; determining, for each of the one or more candidate variable flow control mechanical devices, one or more candidate equipment that are fulfilled by the differential capability; calculating a respective cost of combinations of one or more candidate variable flow control mechanical devices, one or more candidate heat exchangers, and one or more candidate air separators operating together according to the load profile and the one or more candidate variable flow control mechanical devices operating on a respective control curve having a respective setpoint which includes the differential capability from the design setpoint, including iteratively calculating by first iterating respective cost of the one or more candidate variable flow control mechanical devices, second iterating, for the one or more candidate variable flow control mechanical devices from the first iterating, respective cost of the one or more candidate heatexchangers, and third iterating, for the one or more candidate heat exchangers from the second iterating, respective cost of the one or more candidate air separators; generating a priority based on the respective cost of the combinations; receiving selection of one of the combinations; and generating output for configuring the one or more candidate variable flow control mechanical devices of the one of the combinations that is selected with the respective control curve having the respective setpoint which includes the differential capability from the design setpoint.

[0261] Another example embodiment is a system, comprising the at least one processor for performing the method of any one of the above.

[0262] Another example embodiment is a non-transitory computer readable medium having instructions stored thereon executable by at least one controller for performing the method of any one of the above.

[0263] In example embodiments, as appropriate, each illustrated block or module may represent software, hardware, or a combination of hardware and software. Further, some of the blocks or modules may be combined in other example embodiments, and more or fewer blocks or modules may be present in other example embodiments. Furthermore, some of the blocks or modules may be separated into a number of subblocks or sub-modules in other embodiments.

[0264] While some of the present embodiments are described in terms of methods, a person of ordinary skill in the art will understand that present embodiments are also directed to various apparatus such as a server apparatus including components for performing at least some of the aspects and features of the described methods, be it by way of hardware components, software or any combination of the two, or in any other manner. Moreover, an article of manufacture for use with the apparatus, such as a prerecorded storage device or other similar non-transitory computer readable medium including program instructions recorded thereon, or a computer data signal carrying computer readable program instructions may direct an apparatus to facilitate the practice of the described methods. It is understood that such apparatus, articles of manufacture, and computer data signals also come within the scope of the present example embodiments.

[0265] While some of the above examples have been described as occurring in a particular order, it will be appreciated to persons skilled in the art that some of the messages or steps or processes may be performed in a different order provided that the result of the changed order of any given step will not prevent or impair the occurrence of subsequent steps. Furthermore, some of the messages or steps described above may be removed or combined in other embodiments, and some of the messages or steps described above may be separated into a number of sub-messages or sub-steps in other embodiments. Even further, some or all of the steps of the conversations may be repeated, as necessary. Elements described as methods or steps similarly apply to systems or subcomponents, and vice-versa.

[0266] In example embodiments, the one or more controllers can be implemented by or executed by, for example, one or more of the following systems: Personal Computer (PC), Programmable Logic Controller (PLC), Microprocessor, Internet, Cloud Computing, Mainframe (local or remote), mobile phone or mobile communication device.

[0267] The term "computer readable medium" as used herein includes any medium which can store instructions, program steps, or the like, for use by or execution by a computer or other computing device including, but not limited to: magnetic media, such as a diskette, a disk drive, a magnetic drum, a magneto-optical disk, a magnetic tape, a magnetic core memory, or the like; electronic storage, such as a random access memory (RAM) of any type including static RAM, dynamic RAM, synchronous dynamic RAM (SDRAM), a read-only memory (ROM), a programmable-read-only memory of any type including PROM, EPROM, EEPROM, FLASH, EAROM, a so-called "solid state disk", other electronic storage of any type including a charge-coupled device (CCD), or magnetic bubble memory, a portable electronic data-carrying card of any type including COMPACT FLASH, SECURE DIGITAL (SD-CARD), MEMORY STICK, and the like; and optical media such as a Compact Disc (CD), Digital Versatile Disc (DVD) or BLU-RAY (TM) Disc.

[0268] Variations may be made to some example embodiments, which may include combinations and sub-combinations of any of the above. The various embodiments presented above are merely examples and are in no way meant to limit the scope of the example embodiments. Variations of the innovations described herein willbe apparent to persons of ordinary skill in the art having the benefit of the described examples, such variations being within the intended scope of the example embodiments. In particular, features from one or more of the above-described embodiments may be selected to create alternative embodiments comprised of a sub- combination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternative embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and subcombinations would be readily apparent to persons skilled in the art upon review of the example embodiments as a whole. The subject matter described herein intends to cover all suitable changes in technology.

[0269] Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.

Claims

WHAT IS CLAIMED IS:1 . A method for a system having a variable load, the variable load being representable by a first parameter and a second parameter that are correlated, the method being performed by at least one processor and comprising: determining a load profile of the variable load; determining a design setpoint of the variable load; determining one or more candidate variable flow control mechanical devices which have a differential capability from the design setpoint, wherein the differential capability is a pressure variable; determining, for each of the one or more candidate variable flow control mechanical devices, one or more candidate equipment that are fulfilled by the differential capability; calculating a respective cost of combinations of the one or more candidate variable flow control mechanical devices and the one or more candidate equipment operating together according to the load profile and the one or more candidate variable flow control mechanical devices operating on a respective control curve having a respective setpoint which includes the differential capability from the design setpoint, including iteratively calculating by first iterating respective cost of the one or more candidate variable flow control mechanical devices, and second iterating, for the one or more candidate variable flow control mechanical devices from the first iterating, respective cost of the one or more candidate equipment; generating a priority based on the respective cost of the combinations; receiving selection of one of the combinations; and generating output for configuring the one or more candidate variable flow control mechanical devices of the one of the combinations that is selected with the respective control curve having the respective setpoint which includes thedifferential capability from the design setpoint.

2. The method as claimed in claim 1 , wherein the differential capability is an additional capability or additional capacity beyond the design setpoint.

3. The method as claimed in claim 1 , wherein the differential capability is a reduced capability or reduced capacity from the design setpoint.

4. The method as claimed in claim 1 , wherein the one or more candidate variable flow control mechanical devices comprise one or more candidate valves.

5. The method as claimed in claim 1 , wherein the one or more candidate variable flow control mechanical devices comprise one or more candidate variable control pumps.

6. The method as claimed in claim 5, further comprising determining a baseline variable control pump having the design setpoint.

7. The method as claimed in claim 6, wherein one of the candidate variable control pumps includes the baseline variable control pump operating at the differential capability from the design setpoint.

8. The method as claimed in claim 6, wherein the generating the priority includes generating a comparison of respective cost of the baseline variable control pump operating on a control curve including the design setpoint to at least one other of the candidate variable control pumps.

9. The method as claimed in claim 6, further comprising determining a baseline equipment for the baseline variable control pump, wherein the generating the priority includes generating a comparison of respective cost of the baseline equipment to at least one other of the candidate equipment.

10. The method as claimed in claim 5, wherein the calculating the respective cost is for the one or more candidate variable control pumps taking to account respective operation on the control curve of the first parameter versus the second parameter, wherein the control curve includes the setpoint which includes the differential capability from the design setpoint.11 . The method as claimed in claim 10, wherein the one or more candidate variable control pumps are sensorless control pumps that operate on the control curve using at least one self-detected device property without an external sensor.

12. The method as claimed in claim 5, wherein the differential capability is a maximum respective capability of each of the one or more candidate variable control pumps.

13. The method as claimed in claim 1 , wherein the pressure variable is pressure capability, head capability, pressure capacity or head capacity.

14. The method as claimed in claim 5, wherein the one or more candidate variable control pumps include at least two candidate control pumps for parallel operation.

15. The method as claimed in claim 1 , wherein the generating the priority includes recommending one of the combinations having an optimal cost.

16. The method as claimed in claim 1 , wherein the calculating of the respective cost of combinations is based on initial cost and operating cost over a payback period.

17. The method as claimed in claim 1 , wherein the iteratively calculating includes third iterating, for the one or more candidate equipment of the second iterating, respective further cost of further one or more of the candidate equipment which is in a different equipment category than the one or more candidate equipment of the second iterating.

18. The method as claimed in claim 1 , wherein the load profile includes load data with associated time data or load percentage with associated time percentage.

19. The method as claimed in claim 1 , wherein the first parameter is one of the pressure variable or flow, and the second parameter is the other of the pressure variable or the flow.

20. The method as claimed in claim 19, wherein the design setpoint of the system is a maximum pressure at a maximum flow.21 . The method as claimed in claim 1 , wherein the one or more candidate equipment includes a heat exchanger that defines a first fluid circuit and a second fluid circuit.

22. The method as claimed in claim 21 , wherein the one or more candidate variable flow control mechanical devices include one or more first candidate variable flow control mechanical devices for the first fluid circuit and one or more second candidate variable flow control mechanical devices for the second fluid circuit.

23. The method as claimed in claim 1 , wherein the one or more candidate equipment includes an air separator.

24. The method as claimed in claim 1 , wherein the one or more candidate equipment includes two or more candidate equipment, and the calculating the respective cost of the combinations is based on the two or more candidate equipment operating together with the one or more candidate variable flow control mechanical devices according to the load profile.

25. The method as claimed in claim 1 , wherein the control curve is a quadratic control curve.

26. The method as claimed in claim 1 , wherein the output includes program instructions for the configuring the one or more candidate variable flow control mechanical devices of the one of the combinations that is selected.

27. A method for a system having a variable load, the method being performed by at least one processor and comprising: determining a load profile of the variable load; determining a design setpoint of the variable load; determining one or more candidate variable flow control mechanical devices which have a differential capability from the design setpoint, wherein the differential capability is a pressure variable; determining, for each of the one or more candidate variable flow control mechanical devices, one or more candidate equipment that are fulfilled by the differential capability;calculating a respective cost of combinations of one or more candidate variable flow control mechanical devices, one or more candidate heat exchangers, and one or more candidate air separators operating together according to the load profile and the one or more candidate variable flow control mechanical devices operating on a respective control curve having a respective setpoint which includes the differential capability from the design setpoint, including iteratively calculating by first iterating respective cost of the one or more candidate variable flow control mechanical devices, second iterating, for the one or more candidate variable flow control mechanical devices from the first iterating, respective cost of the one or more candidate heat exchangers, and third iterating, for the one or more candidate heat exchangers from the second iterating, respective cost of the one or more candidate air separators; generating a priority based on the respective cost of the combinations; receiving selection of one of the combinations; and generating output for configuring the one or more candidate variable flow control mechanical devices of the one of the combinations that is selected with the respective control curve having the respective setpoint which includes the differential capability from the design setpoint.

28. The method as claimed in claim 27, wherein the control curve is a quadratic control curve.

29. A system, comprising the at least one processor for performing the method of any one of claims 1-28.

30. The system of claim 29, further comprising one of the combinations for operating together in the system.31 . A non-transitory computer readable medium having instructions stored thereon executable by at least one controller for performing the method as claimed in any one of claims 1-28.

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