Integrated designer

Abstract

Systems and methods for selection and operation of variable control pumps for a variable load, which consider number of control pumps, headered operation, cost, pump redundancy, and single versus multiple control pump units. The method comprises: determining a load profile of the variable load; determining a design setpoint of the variable load comprising design head and design flow; determining N candidate variable control pumps in parallel to fulfill the variable load based on the design setpoint; calculating a first cost over a time period of operating the N candidate variable control pumps to fulfill the variable load using the load profile and a first respective control curve of the N candidate variable control pumps for the design setpoint; calculating a total maximum flow capacity at a head setpoint of N-1 of the candidate variable control pumps; and calculating a redundancy factor.

Description

INTEGRATED DESIGNERCROSS-REFERENCE

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 743,092 filed January 8, 2025 entitled INTEGRATED DESIGNER, the entire contents of which are herein incorporated by reference into the Detailed Description herein below.TECHNICAL FIELD

[0002] Example embodiments generally relate to Heating Ventilation and Air Conditioning (HVAC) systems, and selection and operation of variable control pumps 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. The operation of one equipment for a building affects the performance of another equipment that is operating in the same building.

[0007] Redundancy is an important factor as one or more pieces of equipment may fail. Redundancy is often taken into account by a generic multiplication of components, which can result in over capacity for the majority of the time. Other types of redundancy include duty-standby, in which one duty pump is responsible for duty and a backup pump is responsible for standby when the duty pump is unavailable. In some non-headered systems, individual pumps are individually responsible for a different system or chiller, and so may not provide the desired redundancy fail safes for the designer.

[0008] Other difficulties with existing systems may be appreciated in view of the Detailed Description of Example Embodiments, herein below.SUMMARY

[0009] Example embodiments generally relate to selection and operation of variable control pumps in HVAC systems, which consider number, parallel (headered) operation, cost, pump redundancy, and single, dual and multiple control pump units.

[0010] Example embodiments include software, systems and methods to facilitate selection and operation of different variable flow control mechanical devices, such as variable control pumps, for the design point and load profile of a system 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] Example embodiments include a graphical user interface for selecting the appropriate variable control pumps the user as the graphical user interface allow the selection to cater to the building needs with efficient operation and redundancy. Overall costs and operation costs over payback periods are also be considered by the controller.

[0012] The software and user interface includes selection methodology and display output to present the optimum customer value combination for pumps, controls and packaged systems, for fluid flow solutions, that improves customer value in comparison to a customer's specified product or, if not specified, a traditional configuration. In examples, the interface accommodates for users, the location, building type, and criticality of building application. The software can be capable of selecting multiple solutions for varying quantities, including controls systems, pumps, or packaged systems, from total system design conditions. The ranking and display can, by default, list equipment choices in the order of most preferred to the least preferred.

[0013] Examples of priority or most preferred options can include the following criteria: promote the best value solution incorporating “redundancy” and “parallel” options; align with value proposition (lowest first installed cost and lowest life cost); the scope of selections remains competitive and practical in response to the user's requests.

[0014] An example embodiment is a method for 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 comprising design head and design flow; determining N candidate variable control pumps in parallel to fulfill the variable load based on the design setpoint, wherein N is at least 2; calculating a first cost over a time period of operating the N candidate variable control pumps to fulfill the variable load using the load profile and a first respective control curve of the N candidatevariable control pumps for the design setpoint; calculating a total maximum flow capacity at a head setpoint of N-1 of the candidate variable control pumps; calculating a redundancy factor based on the design flow and the total maximum flow capacity at the head setpoint of the N-1 of the candidate variable control pumps; and generating for output the N candidate variable control pumps, the first cost, and the redundancy factor.

[0015] Another example embodiment is a method for a variable load, the method being performed by at least one processor and comprising:a) determining a threshold redundancy factor;b) determining a design setpoint of the variable load comprising design head and design flow;c) determining N candidate variable control pumps in parallel to fulfill the variable load based on the design setpoint, wherein N is at least 2;d) calculating, for operating N-1 of the candidate variable control pumps at a head setpoint, a respective maximum flow capacity of each of the N-1 of the candidate variable control pumps;e) calculating a total maximum flow capacity at the head setpoint using the respective maximum flow capacity of the N-1 of the candidate variable control pumps;f) calculating a redundancy factor based on the design flow and the total maximum flow capacity at the head setpoint based on the respective maximum flow capacity of the N-1 of the candidate variable control pumps;g) determining whether the redundancy factor exceeds the threshold redundancy factor; andh) selecting, when the redundancy factor exceeds the threshold redundancy factor, the N candidate variable control pumps to source the variable load.

[0016] Another example embodiment is a method for controlling a variable control pump installed with at least one other variable control pump in parallel to source avariable load, the method being performed by at least one processor and comprising: operating the variable control pump on a first control curve which includes a design setpoint of the variable load comprising design head and design flow; determining that one of the other variable control pumps is unavailable; and operating, when the one of the other variable control pumps is unavailable, the variable control pump on a second control curve which includes a second design setpoint at maximum flow capacity at a head setpoint.

[0017] Another example embodiment is a system, comprising the at least one processor for performing the method of any one of the above.

[0018] 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

[0019] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments, and in which:

[0020] 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.

[0021] Figure 1 B illustrates a graphical representation of further aspects of the chilled water plant shown in Figure 1A.

[0022] 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.

[0023] 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.

[0024] Figure 1 E illustrates a graphical representation of an example heating plant.

[0025] Figure 1 F illustrates a graphical representation of an example chilled water plant having a direct cooling loop.

[0026] Figure 1 G illustrates a graphical representation of an example heating plant having a district heating loop.

[0027] Figure 1 H illustrates a graphical representation of an example heating plant for heating potable water.

[0028] Figure 11 illustrates a graphical representation of an example building system for waste heat recovery.

[0029] Figure 1 J illustrates a graphical representation of an example building system for geothermal heating isolation.

[0030] Figure 2A illustrates a graphical representation of a heat exchanger, in accordance with an example embodiment.

[0031] Figure 2B illustrates a perspective view of an example heat transfer module with two heat exchangers, in accordance with an example embodiment.

[0032] Figure 20 illustrates a perspective view of an example heat transfer module with three heat exchangers, in accordance with an example embodiment.

[0033] Figure 2D illustrates a partial breakaway view of contents of the heat transfer module of Figure 2C.

[0034] 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.

[0035] Figure 3A illustrates a graphical representation of network connectivity of a heat transfer system, having local setup.

[0036] Figure 3B illustrates a graphical representation of network connectivity of a heat transfer system, having remote setup.

[0037] Figure 4A illustrates a graph of an example heat load profile for a load such as a building.

[0038] Figure 4B illustrates a graphical user interface for configuring the load profile of Figure 4A, in accordance with an example embodiment.

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

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

[0041] Figure 5A illustrates a graph of an example range of operation and selection range of a variable speed control pump for a heat transfer system.

[0042] Figure 5B illustrates a flow diagram of a method of operating a control pump that is selected to operate in the building system, along with other control pumps, having redundancy operation, in accordance with an example embodiment

[0043] Figure 6 shows a diagram illustrating internal sensing control of a variable speed control pump.

[0044] Figures 7A and 7B show a flow diagram illustrating a method for selecting variable speed control pumps, starting by way of either product or application, respectively in accordance with example embodiments.

[0045] Figure 8A shows a graph of an example range of operation of N parallel pumps with redundancy as percentage of flow at design head.

[0046] Figure 8B shows a graph of an example range of operation of N parallel pumps with redundancy as percentage of flow at maximum system head for N-1 pumps.

[0047] Figure 8C shows a chart of example applications and associated minimum recommended redundancy level.

[0048] Figure 9 shows a chart illustrating selection of candidate control pumps, in accordance with an example embodiment.

[0049] Figure 10A shows a flow diagram of an example method for selection of candidate control pumps for a variable load, in accordance with an example embodiment.

[0050] Figure 10B shows another flow diagram of another example method for selection of candidate control pumps, in accordance with an example embodiment.

[0051] Figure 11A illustrates an example graphical user interface of proposed control pumps.

[0052] Figures 11 B-11 D illustrate a value articulation letter of proposed control pumps.

[0053] Similar reference numerals may have been used in different figures to denote similar components.DETAILED DESCRIPTION

[0054] Non-limiting example definitions of some example terms are as follows.

[0055] Annual Operating Cost: The annual operating cost details the energy input for the operating hours of the fluid management system, expressed in the market segment regional currency. The operation is based on a default load profile for the location, building and system types. The default operating hours are also be based on building and system types and location. Defaults may be edited by the user.

[0056] Best Design Envelope (DE) value for system: Using original or edited defaults and system data inputs specification; an optimum combination and quantity of equipment is selected to meet total system design flow and head to display the selections. Ranking of the selections are based on lowest installed motor power for the selection, lowest first installed cost, lowest life cycle cost, acceptable redundancy results for the application, optimized controls and packaging, and favorable comparison to the user's original specified requirement or, if no specification is entered, against the traditional base case for the region.

[0057] Configuration Code: The configuration of each Design Envelope unit is currently expressed in selection software as a range of characters to make up a unique configuration code to identify each unit configuration. A range of Design Envelope Vertical Inline (VIL) and End-Suction (ES) pumping units is currently available to customers for express shipment. The current Design Envelope offering includes a combination of models as Pump-in-a-Box (PiB) units, that are in stock and shipped in aday, or two; and other designated express shipment units, both VIL and ES which are available in, generally, 2-weeks. These units are identified by a configuration code and the software can alert users to the express shipment availability.

[0058] Constant pressure: A control method that maintains the pump differential head pressure at the specified value by adjusting the speed of the pumping unit(s).Design Envelope equipment can also maintain a constant system pressure value, with pressure feedback sensors and sensorless control override.

[0059] Defaults (Editable by users): A user can pre-load values for the input variables that impact the value calculation, such as electrical power cost, square footage for equipment footprint, etc. enabling the software to estimate best system value solution for comparison without full system information, exactly specific to the project site.

[0060] Design Envelope pumps: A range of Vertical Inline and Horizontal pumping units with integrated and stand-alone intelligent controls. The pump offering can include: split coupled pumps and close coupled pumps.

[0061] Design Envelope Controls and Automation Systems: A range of integrated or stand-alone intelligent demand based control product solutions that deliver the best value to the customer through simplicity, ease of use, risk reduction, ability to leverage Design Envelope equipment, ability to leverage sensorless, parallel sensorless pump controller (PSPC) and integrated pumping system (IPS)Zintegrated plant control (IPC) control technology ability to optimize chiller plant performance. Examples of the control product solutions include: Design Envelope controls, with inline Electronically Commutated Motor (iECM); Supplied stand-alone controls; Design Envelope Parallel Sensorless Pump Controller (PSPC) integrated or stand-alone; Design Envelope IPS pump station controller; and Design Envelope IPC plant automation control system.

[0062] First Installed Cost: The first installed cost is of primary interest to mechanical contractors and facility owners. For mechanical contractors, the first cost for installed equipment is the equipment acquisition cost (Manufacturer price or wholesaler price + mark-up) + estimated installation cost. A contractor may wish to compare that with their installation estimation data. For facility owners, the first installed cost includesthe acquisition cost (Wholesaler and / or contractor price + mark-up[s]) + installation cost (Contractor installation) + managerial cost (General contractor).

[0063] Life Cycle Cost (LCC): LCC represents a total ownership cost to acquire, install, operate and maintain the selected equipment for the life of the product. LCC in the software can include First installed cost (described above) and the operating cost and maintenance estimates to operate the fluid management system for a period of years. 25-years is a normal system equipment life expectancy and is available to the user for full LCC calculation. The LCC default for equipment ranking is 5-years. The term may be adjustable by the user as a payback period may be important in some cases.

[0064] Load Profile: The load profile is a key component of the operating cost calculation and can be embedded in the energy cost section of the software. A load profile can detail operating hours for the selected building and system type, and the percentage of time belonging to each system load segment. The load profile may change for the same building type and system type depending on the building location. Defaults can be in place for the software selection, which can be editable by users to more accurately estimated load profiles for their energy needs. The software can convert the load profile into equipment operating loads and on / off status under the base case control scenario and the Design Envelope control scenario (sequences) to accommodate the building cooling or heating load profile and application (example a pump in a constant flow cooling tower application, or a set of 3 parallel pumps with 3 constant flow cooling towers, or variable secondary pump stations, etc,).

[0065] MBH: Thousands of BTU / hr (BTU - energy to raise 1 -lb of water 1 °F (or equivalent kg and degC), about 1055 Joules). 1 MBH is 0.2931 kWh.

[0066] Minimum Maintained Pressure [MMP]: MMP is generally the pressure required to be maintained in closed or open HVAC systems. MMP in open systems is usually required to prevent HVAC equipment that require a minimum inlet pressure, such as pumps, from experiencing problems by maintaining a minimum set pressure, usually be ensuring sufficient head pressure between the source and equipment is maintained. In closed systems MMP may be a concern at remote heat exchangers, such as air handling units (AHU), where a minimum pressure is required to ensure sufficient flow isavailable to service a conditioned space. This can be accomplished by installing a system feedback pressure sensor connected to the HVAC equipment controls, or setting the pressure requirement in intelligent equipment controls to ensure MMP is available to the remote load at all flows.

[0067] Multi-Sensored Zones: Multiple HVAC zones are common where the diversity of occupancy and heat loads may cause difficulty in providing comfort throughout the building. This sometimes cannot be accomplished by sensorless curve control alone. Differential pressure or temperature feedback sensors on many or all zones in the building is one design solution to ensure occupancy comfort. When used, all sensors are monitored and maintained at the desired set-points. Features include design envelope pumps with sensor over-ride, Intelligent Fluid Management System (iFMS) with integrated pumping system (IPS) or integrated plant control (IPC) controller, and IPS and IPC standalone for these applications.

[0068] N, N-1 , N+1 , N+2, 2N: These are terms concerning Design Day duty loading equipment quantity, such as pumps, boilers, and chillers. 'N' is provided as a figure to represent the designer's quantity of equipment required to achieve design day 'duty' loading. N-1 indicates an operating scenario where one of the ' N' duty pieces of equipment required to provide design day duty has failed and will not operate. N+1 is a traditional expression by system designers to include in the design, one additional 'spare I standby' piece of equipment. The (N+1 )th piece of equipment is specified to become duty status in the scenario where one of the duty equipment pieces fails, then the standby equipment may be automatically, or manually, activated to provide available capacity for 100% of the design day conditions. The software includes N+1 and N+2 options, as N+2 may be specified for data centers, where N+2 (Duty equipment + 2-redundant units) or '2N' (Duty equipment is doubled) for a true 100% redundancy.

[0069] Pump Construction: Pump construction is understood in the art and not described in detail where appropriate.

[0070] Quadratic system and control curves: Quadratic curves are displayed on centrifugal pump performance curves. System curves indicate the estimated system resistance in a hydronic system as flow volume changes and typically tracks from zeroflow and head (Origin) to the design flow and head. The system resistance varies with the square of the flow change, meaning that doubling flow in a static system increases resistance by 4. Where the pump curve intersects the system curve is the point of operation. System control valves react to current load requirements and controls will change pump speed to meet the flow needs of variable flow systems as the system resistance changes. Variable speed control changes pump speed so the pump curve and system curve intersect on the quadratic control curve. Linear control curves are typically linear (Straight-line) curves from zero flow head to the duty flow head; though can have a slope from zero (constant pressure) to another value (50% for example) for lower minimum maintained system pressures. Quadratic control curves are curves from a minimum maintained pressure zero flow head to the duty flow head point. All pump, system and control curves are detailed on most variable speed pump performance curves.

[0071] Redundancy: Output of N-1 pieces of equipment operating at maximum speed or maximum motor capability can be expressed as:

[0072] X% of design output with N-1 pieces of equipment at maximum capacity. For pumps this is X% of design flow where N-1 pump curves, running at full speed, intersect the system curve.

[0073] Y% of design output, at design output parameter (e.g. temperature or head). For a pump this is Y% of design flow where N-1 pumps are running at maximum speed and the system curve intersects the pump curve at design head.

[0074] Multi-zone systems are generally under part load; though could require close to design head in some isolated zones.

[0075] Results Grid: The list of individual fluid management solutions (pumping units, iFMS, control solutions) that meet the requirements of the entered data. Users can select specific equipment grids (pumps or iFMS or Controls) in the solution display.

[0076] Risk response for Redundancy <100% selection at N-1 Vs specified 100% redundancy: Minimum redundancy of parallel pumps is ~70% of design flow; though average is >80%. Typical air handling unit heat emission will be ~95% at 70%redundancy levels; higher at higher redundancy levels. Heat emission and possible humidity changes will be negligible if the inlet fluid temperature can be adjusted accordingly.

[0077] Total System Flow: Total system flow is the flow required for each part of the HVAC system to operate properly at the building design conditions (e.g. primary, secondary, tertiary, or condenser systems). It is the sum of the flows from all the duty pumps in any particular system. Total System Flow can be entered directly by the user, or it can be calculated by multiplying duty pump quantity by pump flow.

[0078] TR: Tonnes of Refrigeration. Equivalent to 12,000BTU / hr or 3.517kWh.

[0079] Traditional comparison configuration: When calculating the customer value of user's selections against competitive alternates, there may be occasions when there is no competitive specification, or selection, to compare. In these cases, the comparison will be made against the average 'boiler-plate' product selection, that is seen in most HVAC mechanical rooms and specifications in the region. In the US and ME markets this means a flexibly coupled end-suction base mounted pump with standalone controls (general purpose VFD mounted on a wall or other structure in the mechanical room), along with a sensor placed in the mechanical room (Constant pressure control using standard external sensor price + installation cost, abbreviated to DOW (Drive on wall) in some examples). For individual pump flows greater than 3000gpm 1189lps 16813cu / hr the traditional selection is an Horizontal Split Case (HSC) type. In the other markets (e.g., Canada, UK / Europe, Brazil, APR, and China) VIL units, with a drive on the wall, etc., will default in place of base mounted units.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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. A control pump 102a, 102b can also be denoted as a “pump” for convenience of reference.

[0084] 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 102b can 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 (potable or non-potable), 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, asapplicable. 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.

[0085] 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.

[0086] 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 1A), ambient, or a temperature source. The heat exchanger 118 can be placed in various positions in the building system 100 of Figure 1B. The air separator 132 can be placed in various positions in the building system 100 of Figure 1B, 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 pump speed 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 coilsthat 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.

[0087] 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.

[0088] 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 pump102a, 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, 11 Ob, 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.

[0089] 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, 11 Od), the valves (112a, 112b, 112c, 112d), the control pumps 102a, 102b, the heat exchanger 118, and other equipment and devices.

[0090] Referring again to Figures 1 A 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 flow rate 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 oneor 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.

[0091] 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).

[0092] 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.

[0093] In the configuration of Figure 1 C, the supply flow is usually run at full speed. Since the cooling tower 124 operation is relatively less expensive 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 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 the Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. An example approach temperature of 1F (or applicable delta in Celsius) can be used so that pump energy is not consumed if additional heat exchange is too low.

[0094] 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.

[0095] 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 1F (or applicable delta in Celsius) is recommended so that pump energy is not consumed if additional heat exchange is too low.

[0096] 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.

[0097] 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 the passenger interior of the vehicle. The cool ambient air can pass through bypass piping or valves to bypass the heat exchanger 118 in some examples.

[0098] 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 theloads 110a, 110b, 110c, 110d, which can be parallel loads that are perimeter heating units.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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 1F higher, or equivalent delta Celsius). The recommended control method is Tload, out control or 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.

[0103] 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 wouldbe 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.

[0104] Figure 1G 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.

[0105] 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.

[0106] 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 heated potable 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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 frame200 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)).

[0112] 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 side is called Tsource, in. The water temperature going out of the heat exchanger 118 from the source side is called Tsource, out.

[0113] 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.

[0114] 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 118.

[0115] 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 control valve can include onboard sensors, and may perform self-adjustment, monitoring and control using its controller. The variable control valve can be pressure independent insome examples. The variable control valve can be a 2-way variable control valve in some examples.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] The various sensors can be used to detect and transmit measurement of parameters of the heat transfer module 220. The sensors can include temperaturesensors 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.

[0124] 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.

[0125] 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.

[0126] 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 exchanger118a, 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).

[0127] 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.

[0128] 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.

[0129] 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, each branch 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.

[0130] Suction guides (not shown) can be integrated in the heat transfer module 220, 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.

[0131] 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 1B). 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 client device such as 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.

[0132] 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 client device such as the smart device 304 can access, by way of Internet 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.

[0133] 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.

[0134] 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.

[0135] 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 settingsremotely by connecting to the cloud 308. These settings will be limited depending on security restrictions.

[0136] 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 can automatically 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.

[0137] 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.

[0138] 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.

[0139] 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.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] For example, the cloud 308 may be used as a web portal for access by a client device such as the smart device 304 to facilitate selection of a suitable control pump 102a, 102b, and other equipment such as the heat exchanger 118 and the air separator 132. The cloud 304 may be configured as a web server which generates graphical user interface (GUI) screens for display on the smart device 304. The cloud 308 may include one or more servers.

[0144] The cloud 308 can include memory which stores 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 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 502, and design point regions 540 (e.g., see Figure 5A). The memory 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.

[0145] The smart device 304 may include one or more client applications. In some examples, the smart device 304 may be configured with a web browser which is used to access a web site or web portal of the cloud 308, 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 smart device 304, based on information received from the cloud 308, from memory, or from user input. The smart device 304 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 smart device 304. Some exampleembodiments may include a Virtual Private Network (VPN) or other credential-based access.

[0146] In some conventional selection systems for selecting equipment, equipment may already be categorized into predetermined or hard-coded groups, so that all of the equipment in a group are retrieved depending on the desired search parameters (e.g. all equipment 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 equipment would be most appropriate, which may result in less than optimal selection of an inappropriate or inefficient equipment for the desired end use or design point.

[0147] 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.

[0148] 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 tocalculate heat load (Q) required in the system load 110a, 110b, 11 Oc, 110d of the building 104 in real time.

[0149] 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.

[0150] 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 time is 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).

[0151] 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.

[0152] 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.

[0153] 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.

[0154] The HX card 222 can store individual heat exchanger data, such as heat transfer module model and serial numbers, design points, mapped heat transferperformance 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.

[0155] Service history can be stored on the cloud 308. Service history can be upload to the HX card 222 through Webserver U I, 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.

[0156] 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, Udirt (overall heat transfer coefficient of heat exchanger after some time of operation), and the heat exchanged (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).

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] Figure 4B illustrates a graphical user interface 410 for configuring the load profile of Figure 4A, in accordance with an example embodiment.

[0163] 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 equipment such as the control pump 102a, 102b, and other equipment of the building system 100 such as the heat exchanger 118, when the building 104 operates most of the time below 50% flow of duty capacity (100%).

[0164] 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 can be modelled based on the initial input options, and manually adjusted though the graphical user interface 440 through design or real-time measurement.

[0165] 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.

[0166] One feature of the graphical user interface 440 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 control pump 102a, 102b, and / or other equipment. The load profile can be defined for different building types and shifted per ASHRAE (RTM) procedures for different locations.

[0167] In other examples of the graphical user interface 440, 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.

[0168] Figure 5A illustrates a graph 500 of an example range of operation and selection range (design point region 540) of a variable speed control pump 102 for a building system 100. The design point region 540 may be referred to as a "selection range", "composite curve" or "design envelope" for a particular control pump 102.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.

[0169] In an example, the graphical user interface is capable of displaying wire-to-water (WtoW) efficiencies as well the hydraulic efficiency. WtoW efficiency accounts for the losses in the motor, drive, and mechanical systems. WtoW losses are to be added to outputs and tables. The graphical user interface may include a toggle button to switch between the hydraulic efficiency curves and the WtoW curves. In an example, the pump hydraulic efficiencies are first displayed as standard default to start, until the toggle button is selected. The efficiencies and toggle buttons can be output along with the recommended or priority control pumps 102.

[0170] The range of operation 502 is illustrated as a polygon-shaped region or area on the graph 500, wherein the region is bounded by a border represents a suitable range of operation 502. A design point region 540 is within the range of operation 502 and includes a border which represents the suitable range of selection of a design point for a particular control pump 102, e.g. point A (510) in this example. The design point region 540 may be referred to as a "selection range", "composite curve" or "designenvelope" for a particular control pump 102. In some example embodiments, the design point region 540 may be used to select an appropriate model or type of control pump 102 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 (510) 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 500, and any control pump 102a that overlaps with the design point region 540 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. In examples, the graphical user interface is generated by a server, a client device (e.g. smart device 304), or a combination thereof.

[0171] 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.

[0172] The determining of the design point can include receiving the design point through the graphical user interface.

[0173] The graph 500 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 504 illustrates flow in U.S. gallons per minute (GPM) (alternatively litres / m inute) and the ordinate or y-axis 506 illustrates head (H) in feet (alternatively in pounds per square inch (psi) or metres). The range of operation 502 is a superimposed representation of the control pump 102 with respect to those parameters, onto the graph 500.

[0174] As shown in Figure 5A, one or more control curves 508, 508’ (two shown) may be defined and programmed for an intelligent variable speed device, such as the control pump 102. Depending on changes to the detected parameters (e.g. external or internal detection of changes in flow / load), the operation of the control pump 102 may be maintained to operate on the same control curve 508 based on instructions from the 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 508 is a quadratic curve between two operating points (e.g., point A (510): maximum head, and point C (514): minimum head which can be calculated as 40% of maximum head).Reference to "intelligent" devices herein includes the control pump 102 being able to selfadjust operation of the control pump 102 along the control curve 508, depending on the particular required or detected load. A thicker region on the control curve 508 represents the average load when operating to source the building 104.

[0175] The design point region 540 can be optimized for selection of an appropriate control pump 102 through a graphical user interface, that takes into account the heat exchanger 118 in the system 100. In view of Figure 5A, an example embodiment is a method performed by the controllers 116 for selecting a variable speed device, such as one or both control pumps 102, 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 outputting (e.g., sending or displaying) N candidate control pumps 102 which collectively satisfy the design point to source the system load. The method can include selecting, or receiving selection of, the candidate control pumps 102 through the graphical user interface. The method can include installing and operating the selected control pumps 102 in the building system 100.

[0176] In an example, the selected control pump 102 can operate at an increased flow, or at maximum flow allowable. The quadratic pressure control (QPC) can use this increased head value as the new setpoint (e.g., point A’ (510’)) for the control pump 102,using the QPC and control curve 508 calculation noted above to the new control curve 508’. The control curve 508’ shown is a quadratic from point A’ (510’) to the original point C (514) which is minimum head. In such an example, the increased flow can be used for redundancy to account for another parallel control pump 102 being unavailable, such as inoperative, malfunctioning, maintenance, etc.

[0177] Another example control curve, not shown here (best shown in Figure 8B), has a control setpoint for maximum flow at the maximum system head for N-1 pumps.

[0178] In some examples, additional capability or capacity required for the candidate control pump 102 includes a head capacity or a power capacity that is available from the candidate control pump 102 in order to account for the increased pressure caused by other equipment such as the heat exchanger 118.

[0179] Examples for the setpoint (design point) include selecting of two (or more) parallel pumps that achieve the setpoint, which includes dividing maximum flow into half or other suitable apportionments (e.g. equally or unequally). For multiple control pumps 102 in parallel, for a given setpoint, the flow setpoint can be divided and apportioned accordingly (evenly or otherwise) between the parallel control pumps 102, so that each control pump 102 can be autonomously individually in charge of a particular amount of flow setpoint. When one of the parallel control pumps 102 is unavailable, the remaining control pumps 102 can operate redundantly onto the new control curve 508’ to fulfill the flow deficiency.

[0180] In an example, the controllers 116 can instruct the control pump 102 as to which control curve to operate, e.g., based on either of point A (510) or point A’ (510’). In examples, the controllers 116 can instruct the control pump 102 that one of the parallel control pumps 102 is unavailable, and the control pump 102 can operate on the control curve 508’ related to redundancy operation.

[0181] Another example control curve represents the control curve required to satisfy the entire system setpoint by collective operation of N pumps or N-1 pumps, and each control pump 102 thus operates on their own respective control curve as appropriate to collectively achieve the system control curve.

[0182] Another example embodiment of a variable speed sensorless device is a compressor which estimates refrigerant flow and lift from the electrical variables provided by the electronic variable speed drive. In an example embodiment, a "sensorless" control system may be used for one or more cooling devices in a controlled system, for example as part of a "chiller plant" or other cooling system. For example, the variable speed device may be a cooling device including a controllable variable speed compressor. In some example embodiments, the self-detecting device properties of the cooling device may include, for example, power and / or speed of the compressor. The resultant output properties may include, for example, variables such as temperature, humidity, flow, lift and / or pressure.

[0183] Another example embodiment of a variable speed sensorless device is a fan which estimates air flow and the pressure it produces from the electrical variables provided by the electronic variable speed drive.

[0184] Another example embodiment of a sensorless device is a belt conveyor which estimates its speed and the mass it carries from the electrical variables provided by the electronic variable speed drive.

[0185] Figure 5B is a flow diagram of a method 550 of operating the control pump 102 that is selected to operate in the building system 100 (along with other control pumps 102 in parallel to source the variable load) having redundancy operation, in accordance with an example embodiment. The method 550 operates the control pump 102 on at least one control curve 508, 508’ within the range of operation 502 (Figure 5A). In examples, the method 550 is performed by at least one processor, such as the control device 108. For example, the processor may determine that one of the other variable control pumps 102 in parallel is unavailable. The method 550 is described in a relation to one control pump 102, with the understanding that the remaining available operating parallel control pumps 102 can also be controlled in a similar manner in some examples.

[0186] At step 552, the method 550 includes operating the variable control pump 102 on a first control curve 508 which includes a design setpoint 510 of the variable load comprising design head and design flow. At step 554, the method 550 includes determining that one of the other variable control pumps 102 is unavailable. For example,control device 108 of the method 550 can receive a message from the controller 116 (Figure 1 B) or from one of the other control pumps 102 that the one of the other variable control pumps 102 is unavailable. Reasons for unavailability of the other variable control pump 102 can include scheduled maintenance, damage, replacement.

[0187] At step 556, the method 550 includes operating, when the one of the other variable control pumps 102 is unavailable, the variable control pump 102 on a second control curve 508’ which includes a second design setpoint 510’ at maximum flow capacity at the design head.

[0188] The method 550 can also include determining that the one of the other variable control pumps 102 is now available, and operating the variable control pump 102 once again on the first control curve 508 which includes the design setpoint 510. In examples, the remaining available parallel control pumps 102 and the newly available control pump 102 that was unavailable can also operate according to their respective first control curve 508 which includes the design setpoint 510.

[0189] The method 550 can operate the control pump 102 in a sensorless manner (as in Figure 6) or with on or more external sensors 114 (Figure 1 B).

[0190] In an example, the first control curve is a quadratic control curve from the design setpoint to a minimum head value, and wherein the second control curve is a second quadratic control curve from the second design setpoint to the minimum head value.

[0191] In an example, the variable control pump includes an internal power sensor for detecting internal motor power and an internal speed sensor for detecting internal motor speed, wherein the processor is configured to map the internal motor power and the internal motor speed to head and flow.

[0192] In an example, the first control curve is a quadratic control curve from the design setpoint to a minimum head value, and wherein the second control curve is a second quadratic control curve from the second design setpoint to the minimum head value.

[0193] In an example, the minimum head value is on or about 40% of the design head.

[0194] In an example, the head setpoint is maximum system head for (N-1) pumps, wherein N is a total number of pumps including the variable control pump and the at least one other variable control pump, wherein the (N-1) pumps is N minus the one of the other variable control pumps that is unavailable.

[0195] In an example, the head setpoint is the design head.

[0196] In an example, the maximum flow capacity is limited by motor speed and / or motor power of the variable control pump.

[0197] In an example, the variable control pump is a sensorless control pump that operates on the first control curve and the second control curve using at least one selfdetected device property without an external sensor.

[0198] In an example, the determining that the one of the other variable control pumps is unavailable comprises receiving a message.

[0199] In an example, the variable control pump and the one of the other variable control pumps that is unavailable are part of a multiple pump unit.

[0200] In an example, at least the operating the variable control pump on the second control curve provides redundancy for the one of the other variable control pumps that is unavailable.

[0201] In an example, at least the operating the variable control pump on the second control curve satisfies a redundancy factor that exceeds a threshold redundancy factor.

[0202] In an example, the calculating the redundancy factor is calculated as:_ . > , ,>% Redundancywherein:N is a total number of pumps including the variable control pump and the at least one other variable control pump;(N - 1 )Pumps is N minus the one of the other variable control pumps that is unavailable; andthe total maximum flow capacity is for the (N-1)PumpSat the head setpoint.

[0203] In an example, the threshold redundancy factor is based on a building type of the variable load.

[0204] In an example, the threshold redundancy factor is: at least 100% when the building type is labelled as mission critical; at least 85% when the building type is labelled as highly comfort sensitive; or at least 70% when the building type is labelled as generic.

[0205] In an example, the threshold redundancy factor is: at least 100% when the building type is a data center, critical care, blood bank, laboratory, research and development center, or hospital; at least 85% when the building type is a university campus, commercial, hotel, office, mixed use, or outpatient center; or at least 70% when the building type is a school, an apartment, a condominium, a religious institution, a factory, or a warehouse.

[0206] 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.

[0207] 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.

[0208] 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 from the 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.

[0209] Figure 6 shows a diagram 600 illustrating internal sensing control of a variable speed control pump 108. The control device 108 for each control pump 102 may include an internal detector 604 or sensor, typically referred to in the art as a “sensorless” control pump because an external sensor is not required. The internal detector 604 may be configured to self-detect, for example, device properties such as the power and speed of the pump device 106. Other input variables may be detected. The pump speed of the pump device 106 may be varied to achieve a pressure and flow setpoint, or a temperature and heat load setpoint, of the pump device 106 in dependence of the internal detector 604. A program map 602 may be used by the control device 108 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.

[0210] 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).

[0211] Variations may be made in example embodiments. Some example embodiments may be applied to any variable speed device, and not limited to variablespeed 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 X parameters on a X-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 on parameters or variables such as liquid, temperature, viscosity, suction pressure, site elevation and number of devices or pump operating.

[0212] Figures 7A and 7B show a flow diagram illustrating a method for selecting variable speed control pumps, starting by way of either product or application, respectively in accordance with example embodiments.

[0213] The method includes two selection tracks. For “Product” selections; where users “just need a pump selection”. This track relies mainly on defaults and requires minimum data from the user. Pump flow and head may be the only data the user has available at the time of selection. Detailed options are available for this track; though may not be well used. The other track is for “Application” selections which tend to be more complicated than the product track requirements. More information may be required from a combination of defaults and user option inputs, to find the optimum customer fluid-flow management solution

[0214] Referring to Figure 7A, the “Product” track will now be described in greater detail. The “Products” track enables the customer to select items such as commercial pumps, circulators, boosters, an iFMS packaged solution, or an integrated plant package (IPP) from input data.

[0215] Selecting product from total system flow and head. This includes iterations of single and multiple parallel pump combinations and appropriate controls to enable optimization of the pumping package.

[0216] Embedded installation estimation software which enables real-time first customer installed cost estimates to be established, for the comparison of optimized equipment against specified product

[0217] Multiple selections of varying quantities of units for the same input data, each with various percentages for system flow to drill down to the optimum customer offering.

[0218] A redundancy calculation to identify redundancy flow available against the design flow, should one pumping unit fail.

[0219] New customer output module which compares the optimum offering against equipment specified by others and I or other product offerings .

[0220] Parallel curves is used to support the parallel selections. This includes correct display of parallel curves, that emulate the single pump curves (e.g. can include end-of-curve clarification data for selections, sensorless control and redundancy). For HVAC headered primary systems new input are required to correctly understand the parallel staging points for accurate energy estimation.

[0221] Defaults are used for various items in the software.

[0222] For Design Envelope (DE) selections, defaults for control curve minimum maintained pressure (MMP) are 40% of design pump head for quadratic control curve and 100% of design head for Constant Pressure applications. The new feature is where the default value data is stored and how it can be edited by a user. The MMP value for all pump selections resides in the system configurator at the appropriate design head default ratios for the application and system type. The editable MMP value is to be expressed as a number, to 1 -decimal in the design head units. Note that MMP should be available for variable speed pumping units in open and closed system configurations.

[0223] Recommendations for redundancy is to be met by selected equipment.

[0224] New user editable load profiles can vary according to the location, building and system types.

[0225] Best efficiency staging includes parallel pumping and staging.

[0226] For selections above 1 -pumping unit, individual selection results grids may not be immediately visible to the user. The program can solve all the optimum solutions and present the results, with value added ratios, to the user. Value added ratios includeratios of the lowest LCC, installed cost and operating costs + payback, if applicable, detailed in the user output screen. Should the user then want more information or options on the product they can click on any of the optimum solutions for more details and an opportunity to make changes to better suit their system.

[0227] Pump operation in the sensorless range is critical, particularly for parallel selections. When pumps operate at rated duty and one pump fails, N-1 parallel pumps may not supply the rated flow and head but the operating point will still be on the quadratic system curve line between the duty point and the minimum system pressure. If this operating point is not in the sensorless range, the system will not perform properly so this condition should be checked.

[0228] Flow turndown sensorless control and flow metering for pumping system.

[0229] The software user can be able to specify system flow turndown with sensorless control for flow metering of the pumping system. A question in the Application track can ask for a turndown value. Units are by ratio or percentage of the design day flow. Default can be: Ratio 1:1 and Percentage 100%. All values entered can be compared to + / - 5% flow readout accuracy of 30% of the full nominal speed BEP flow, for that equipment model. Thus, for turndown values >3.33 / : 1 or >30%, a single pump may suit, providing the design point is at, or right of, the full nominal speed BEP flow. For lower turndowns, multiple pumps, including dual pumps may be applied, until 30% of the last operating model’s full nominal speed BEP flow is at, or below, the required turndown value. Equipment selections from 1 to 6 units are described in detail herein.

[0230] The selection software can display the turndown ratio requested and achieved on customer facing documents; such as: quotes, submittals and orders.

[0231] Referring to Figure 7B, the “Application” track will now be described in greater detail. Example system flow information windows are to be displayed, including: Total System Flow I Flow per Pump Mtr I Pump Mtr Qty I Standby Mtr Qty I Total System Load / Delta T [DT],

[0232] For flow volume (gpm) from total system load and DT use:

[0233] Cooling: Based on TR (Tonnes of Refrigeration) and DT (Temperature Differential); / I ' | ' TO

[0234] For Chilled Water (Primary or secondary) CHW type system: gpm =dt(alternatively Ipm);30*TR

[0235] For Condenser Water type system: gpm =dt(alternatively Ipm):

[0236] Heating: Base on MBH (1000 BTU[IT] / hr) (about 1055 Joules) and DT:

[0237] For Heating: gpm =(alternatively Ipm)

[0238] Users can enter value they think appropriate for their needs.

[0239] System head value is also required.

[0240] For primary headered systems: the general features are 1. Head value input through dedicated piping (chiller I boiler inlet header inlet connections to chiller I boiler output header outlet connections) and 2. Head value input through common piping (piping from chiller I boiler output header outlet connections to chiller I boiler input header inlet connections).

[0241] Pump selections from application section can be similar to the product selections. The main difference is that there is enough information to use iFMS for 2 or 3-installed pumps, IPC for up to 5-units, IPS for up to 6-units in parallel or PSPC for control of up to 4-pump motors; for comparison with customer specification and I or the optimum solution from ranking.

[0242] Pumps are selected from questions answered for:

[0243] Total system flow as given or Flow of one pump motor * number of duty pump motors or from system load and DT and head;

[0244] Pump type specified;

[0245] Quantity of pumps, including standby;

[0246] Building location for load profile;

[0247] List of building types for cooling or heating;

[0248] Selections for the system type (heating, cooling, DCW pressure boosting, evaporative and geothermal, etc.).

[0249] Default values in place, or edited by the user, from building type and location, such as redundancy expectation, load profile, units, electrics, electrical cost, labor cost, traditional comparison configuration.

[0250] Should the answer to the number of sensored-zones question be 1 or 2, control options for parallel system types are (Default) Sensor with sensorless control over-ride. Pricing is to be calculate for each and ranked on the selection grid.

[0251] Should the answer to the number of sensored-zones question greater than 2, control options for parallel system types are PSPC for up to 4-pump motors, up parallel sensorless to 6-pump motors, IPC (For control of up to 5-pumps) and iFMS system for 2 or 3 pumps.

[0252] Note that for multi-sensored zones systems, as a default the multi-pump parallel curve flow data, for less than total number of pumps (N-1 for example) is derived from where the (N-1, for example) pump curve intersects the (Constant Pressure) design head value and not, like the other selections, the full flow system curve. This can include a “toggle” on the parallel curve to display the flow at the intersection of the full flow system curve for use when it is appropriate. The redundancy calculations are described in greater detail herein.

[0253] Selections for the system type and editing I retaining of defaults can lead to the requirement screens for each of the systems selected (heating, cooling, DCW pressure boosting, evaporative and geothermal).

[0254] The requirement screen for each of the systems can lead into selections for:

[0255] System type configuration which include Primary, Secondary (default), Tertiary and Condenser (where the user should be able to select multiple configurations in one go for the same total system flow, with the various individual system heads);

[0256] System flow / head and quantities of each piece of related equipment (boilers, pumps, chillers);

[0257] Default values for system flow (e.g. based on tonnes of cooling (TR) specified, define the default for condenser flow) and DT;

[0258] For Primary and Condenser systems with >1 equipment quantity, a question can ask for “dedicated” or “headered” piping. The answer can affect the selection for pumping units.

[0259] Note that no parallel selection with all duty units (<100% redundancy) should satisfy the following: Allow N-1 flow to exceed the maximum sensorless flow range for the selected pumps; and Work at 85% of the original design head. If the top two rankings of pumps cannot satisfy these items, move on to next selection volume set that will maintain the flow volume in the sensorless zone, in N-1 operation.

[0260] Examples of the redundancy calculation will now be described in greater detail. Figure 8A shows a graph of an example range of operation of N parallel pumps with redundancy as percentage of flow at design head. Figure 8B shows a graph of an example range of operation of N parallel pumps with redundancy as percentage of flow at maximum system head.

[0261] The capability of N-1 pumps deliver a percentage of the design flow and is shown in the ranking grid as part of the value articulation. If the proposed solution has a single pump the redundancy is 0%. If the proposed solution has standby pumps the redundancy is 100%.

[0262] Figure 8C shows a chart of example applications and associated minimum recommended redundancy level. The chart shows Redundancy level (Min), Building type, N= Number of Duty chillers, Chilled Water, Condenser Water, Variable Secondary.

[0263] Redundancy limit tolerance: Should the Redundancy value, from an N-1 calculation, prove to be within 98% of the minimum redundancy level selected, the selection is saved in the grid, at a lower level than selections meeting the minimum requirement, providing it has lower Operating Cost, 1st Installed Cost and 5-yr LCC, than other selections that meet the redundancy limit

[0264] For constant pressure applications, the system curve can change to intersect the constant pressure line and the curve for the number of pumps selected in a dropdown box.

[0265] The quadratic system curve includes the intersection points with all pumps detailed in an editable table. A user can amend the flow for the highest number of pumps curve and the system curve moves to that flow, at the appropriate head, and amend the original data to match. The single pump data can automatically change to reflect the changes. All Design Envelope single pump curves are dynamic in the same way. If a user wants to know the pump head at a different flow on the same pump curve, the user can change the single pump flow and the other curve information changes in sync.

[0266] At N-1 the maximum capability is available on the multi-pump curve for the redundancy calculations.

[0267] The Net Positive Suction Head Required (NPSHR) is to be identified at N-1 flow. Net Positive Suction Head Available (NPSHA) recommendation is 130%*NPSHR. NPSHA, from the data available, should be identified and compared to 130%*NPSHR. If the NPSHA value is less than the 130%*NPSHR, the pressure value lacking is to be identified and a pop-up warning is triggered; similar to single pump NPSH warning.

[0268] For a system with N pumps, the redundancy is calculated based on the capability remaining with N-1 pumps. For these calculations the multipump curves and display in the software should updated to show the maximum power limit for DE pumps.

[0269] The redundancy calculation can be calculated with the following options. Option 1 (Figure 8A): Percentage of flow at design head (for constant pressure and multi-sensored zones selections). Option 2: Percentage of flow at system head (for all Quadratic operating curve selections) example with 2 pumps.

[0270] Referring to Figure 8A (Option 1 ), for N duty pumps in the system, find the maximum flow with N-1 pumps running by maintaining the design head constant. On the individual pump curve, the “max flow” will be the intersection of the design head line with the end of the envelope (or maximum pump speed curve). If the pump exceeds the maximum power available at this flow the pump must slow down. The new speed issimply the cube root of the power multiplied by the current speed. If the pump is not at the maximum power limit, the pump must be sped up until it reaches the maximum power.

[0271] % Redundancy

[0272] Example (Redundancy Option 1):

[0273] N = 3 pumps running;

[0274] (N-1 ) = 2 pumps running if 1 pump fails;

[0275] System design flow and head = 2400 gpm 160 feet (alternatively Ipm / m);

[0276] Per pump: 800 USgpm 160 feet (alternatively Ipm / m);

[0277] Maximum flow at design head (Point Ri): 840 gpm 160 feet (alternatively Ipm / m) for each remaining pump;

[0279] % RedundancyOptionl= 70 %.

[0280] Referring to Figure 8B (Option 2): Percentage of flow at system head (All quadratic operating curve selections) example with 2 pumps. For N duty pumps in the system, find the maximum flow with N-1 pumps for the maximum system head point. On the parallel pump curve, this “max flow” is the intersection of the maximum pump speed for N-1 pumps with the design system curve. If the pump exceeds the maximum power available at this flow the pump must slow down. The new speed is simply the cube root of the power multiplied by the current speed. If the pump is not at the maximum power limit, the pump must be sped up until the pump reaches the maximum power.

[0281] % Redundancy

[0282] Example (Redundancy Option 2):

[0283] N = 3 pumps running;

[0284] N-1 = 2 pumps running if 1 pump fails;

[0285] System design flow and head = 2400 gpm 160 feet (alternatively Ipm / m);

[0286] Control method: Quadratic curve;

[0287] Per pump: 800 USgpm 160 feet (alternatively Ipm / m);

[0288] Maximum system flow at maximum operating speed at system head (Point R2): 2000 gpm 140 feet ;

[0289] 100;

[0290] % RedundancyOption2= 83 %.

[0291] Examples of the Life Cycle Costs (LCC) calculation will now be described in greater detail. In an example, the energy cost includes:

[0292] 1 ) The flow I load profile are based on default I edited values for location and building type.

[0293] 2) The calculations for the energy use combine both the flow profile and the default I edited values for the control method. Editable energy costs are defaulted for the location.

[0294] 3) The calculations for installed cost, maintenance cost and payback are based on the default I edited values for the labour cost.

[0295] Installed cost calculations include:

[0296] 1 ) Pipe size estimates for total system flows to 100,000 gpm (alternatively 378,500 Ipm), for system headers and drop piping to all pumps. Headers and pipe drops may use a default library, and can expanded for a new range of products, sensor(s) installation, and controls. Pipe sizes is based on current ASHRAE 90.1 standards and operating hours reflected in the project load profile.

[0297] 2) Traditional fittings and added-value fittings are to be available; such as Suction Guide versus an inline strainer, long radius elbow and straight pipe run.

[0298] 3) Additional items, such as pipe hangers for iFMS comparisons.

[0299] 4) Total system flow with 1 to 6 number of pumps, including capability for existing 15-pump selection, if appropriate.

[0300] 5) Pump type.

[0301] 6) Additional items can include: VFD wiring, PSPC savings, Soft starters, Commissioning, VFD, Line reactors, VFD bypass savings, Sensor acquisition and installation, Installation cost estimates.

[0302] An additional input for contractor markup can be included as a percentage of the installed cost. The total installed cost can be shown or with the markup separately.

[0303] LCC calculations include the owner cost to purchase the equipment, the estimated installation cost of the equipment and the energy and maintenance estimated to operate the pumping unit for a period of years. 25-years is a normal system equipment expectation though 5-yr LCC can be the default to avoid the 25 years of energy and maintenance dominating the LCC.

[0304] Examples of the selection software (or method) is now described in greater detail, referring to Figure 9, which shows a chart illustrating output and results of the method for selection of candidate control pumps, in accordance with an example embodiment.

[0305] Step 1. Receive customer selection. Select lowest installed cost equipment of the type specified, or local traditional configuration if not specified. BMS means Building Management System.

[0306] Step 2. Select VIL equivalent of specified equipment (if not already VIL). Select split-coupled or close coupled as the specified product.

[0307] Step 3. Select Design Envelope VIL equivalent of specified equipment (if not already specified). Select split-coupled or close coupled as the specified product. Steps 1-3 are single pump items and redundancy is noted as 0%.

[0308] Step 4. Select the control strategy (or application) and redundancy requirement, or use defaults based on the control strategy (or application).

[0309] Step 5. Select 2 to 6 single Design Envelope VIL equivalent duty units for appropriate % flow each, at specified head; and PSPC, IPS, or IPC, as appropriate from Step 4.

[0310] Step 6. Review redundancy requirements for the application and compare with N-1 flow vs. design flow for all units.

[0311] Step 6a. Check redundancy for each selection and, if necessary, increase percentage of design flow in 10% increments (on original % of system flow, not previous value), until redundance requirement is met.

[0312] Step 6b. The increasing redundancy, and % of design flow in each unit, is performed by increasing the unit speed to the motor power limit or speed limit.

[0313] Step 6c. Stop at the previous model (iteration) if model at higher quantity or percentage of flow does not add customer value (e.g. LCC).

[0314] Step 7. Selected dual (or higher) pump units for 2 and 4 motor selections; and PSPC. Check redundancy and, if necessary, increase percentage of design flow (e.g. 10% increments calculated from the initial design flow, iterated up to 50%) until redundancy requirement is met.

[0315] Step 8. Output customer option options in a grid. Record and display redundancy.

[0316] Figure 10A shows a flow diagram of a method 1000 for selection of candidate control pumps 102 for a variable load, in accordance with an example embodiment. In an example, the method 1000 is performed by at least one processor, such as the smart device 304 (Figure 3B), the cloud 308 (Figure 3B), the controller 116 (Figure 1A), or a webserver. At step 1002, the method 1000 includes determining a load profile of the variable load. At step 1004, the method 1000 includes determining a design setpoint of the variable load comprising design head and design flow. At step 1006, the method 1000 includes determining N candidate variable control pumps in parallel to fulfill the variable load based on the design setpoint, wherein N is at least 2. At step 1008, the method 1000 includes calculating a first cost over a time period of operating the N candidate variable control pumps to fulfill the variable load using the load profile and a first respective control curve of the N candidate variable control pumps for the design setpoint. At step 1010, the method includes calculating a total maximum flow capacity at a head setpoint of N-1 of the candidate variable control pumps. At step 1012, the methodincludes calculating a redundancy factor based on the design flow and the total maximum flow capacity at the head setpoint of the N-1 of the candidate variable control pumps. At step 1014, the method 1000 includes generating for output the N candidate variable control pumps, the first cost, and the redundancy factor.

[0317] In an examples, the output includes output for configuring the one candidate variable control pump with the first respective control curve at the head setpoint and the flow setpoint. In an example, the output includes output for configuring the one candidate variable control pump with a second respective control curve which includes a second design setpoint at a higher design flow (e.g. maximum design flow capacity) at the head setpoint. The output can include program instructions for the candidate variable control pump, a message, or a user output interface.

[0318] In an example, the method further includes: determining one candidate variable control pump to fulfill the variable load using the design setpoint; and calculating a second cost of the one candidate variable control pump to fulfill the variable load using the load profile and a second respective control curve of the one candidate variable control pump for the design setpoint, wherein the generating for output includes the one candidate variable control pump and the second cost.

[0319] In an example, the determining the one candidate variable control pump comprises selecting the one candidate variable control pump that fulfills the design setpoint which has a lowest first installed cost.

[0320] In an example, the method further includes selecting the N candidate variable control pumps which have a lowest differential cost from the second cost to the first cost.

[0321] In an example, the generating for output includes generating output for configuring the one candidate variable control pump with the first respective control curve and the second respective control curve.

[0322] In an example, the generating for output includes respective parallel operation pump curves for all of 1 to the N candidate variable control pumps.

[0323] In an example, the head setpoint is the design head.

[0324] In an example, the head setpoint is maximum system head for the N-1 of the candidate variable control pumps.

[0325] In an example, the calculating the redundancy factor comprises calculating:the total maximum flow capacity* quantity (N — l)pUmps% Redundancy = the design flow 100.

[0326] In an example, the method further includes selecting the N candidate variable control pumps which have the first cost which is lowest.

[0327] In an example, the first cost includes a life cycle cost.

[0328] In an example, the method further includes: iterating, by increasing a pump capability, increasing a number of the N candidate variable control pumps, and / or increasing a pump number per multi-pump unit: the determining the N candidate variable control pumps in parallel and the calculating the first cost until the first cost reaches a local minimum.

[0329] In an example, the pump capability includes casing size, motor power, and / or motor speed.

[0330] In an example, the method further includes repeating the determining the N candidate variable control pumps in parallel and the calculating the first cost for different combinations of pump capability, number of the N candidate variable control pumps, and / or increasing a pump number per multi-pump unit.

[0331] In an example, the pump capability includes casing size, motor power, and / or motor speed.

[0332] In an example, at least two of the N candidate variable control pumps are in a multiple pump unit.

[0333] In an example, the method further includes selecting or receiving selection of the N candidate variable control pumps for installation to source the variable load.

[0334] In an example, the method further includes operating the N candidate variable control pumps to source the variable load.

[0335] In an example, the method further includes determining a threshold redundancy factor; determining whether the redundancy factor exceeds the threshold redundancy factor; and selecting, when the redundancy factor exceeds the threshold redundancy factor, the N candidate variable control pumps to source the variable load.

[0336] In an example, the method further includes determining a building type of the variable load, wherein the determining the threshold redundancy factor is based on the building type.

[0337] In an example, the threshold redundancy factor is at least 100%, at least 85%, or at least 70%.

[0338] In an example, the threshold redundancy factor is: at least 100% when the building type is labelled as mission critical; at least 85% when the building type is labelled as highly comfort sensitive; or at least 70% when the building type is labelled as generic.

[0339] In an example, the threshold redundancy factor is: at least 100% when the building type is a data center, critical care, blood bank, laboratory, research and development center, or hospital; at least 85% when the building type is a university campus, commercial, hotel, office, mixed use, or outpatient center; or at least 70% when the building type is a school, an apartment, a condominium, a religious institution, a factory, or a warehouse.

[0340] In an example, the generating for output includes generating output for configuring the N candidate variable control pump with the first respective control curve and a second respective control curve which includes the total maximum flow capacity at the head setpoint.

[0341] Figure 10B shows a flow diagram of a method 1050 for selection of candidate control pumps 102 for a variable load, in accordance with an example embodiment. In an example, the method 1050 is performed by at least one processor, such as the smart device 304 (Figure 3B), the cloud 308 (Figure 3B), the controller 116 (Figure 1A), or a webserver.

[0342] At step 1052, the method 1050 includes determining a threshold redundancy factor. At step 1054, the method 1050 includes determining a design setpointof the variable load comprising design head and design flow. At step 1056, the method 1050 includes determining N candidate variable control pumps in parallel to fulfill the variable load based on the design setpoint, wherein N is at least 2. At step 1058, the method 1050 includes calculating, for operating N-1 of the candidate variable control pumps at a head setpoint, a respective maximum flow capacity of each of the N-1 of the candidate variable control pumps. At step 1060, the method 1050 includes calculating a total maximum flow capacity at the head setpoint using the respective maximum flow capacity of the N-1 of the candidate variable control pumps. At step 1062, the method 1050 includes calculating a redundancy factor based on the design flow and the total maximum flow capacity at the head setpoint based on the respective maximum flow capacity of the N-1 of the candidate variable control pumps. At step 1064, the method 1050 includes determining whether the redundancy factor exceeds the threshold redundancy factor. At step 1066, if the redundancy factor exceeds the threshold redundancy factor (if “Yes”), the method 1050 includes selecting the N candidate variable control pumps to source the variable load.

[0343] At step 1064, if the redundancy factor is below the threshold redundancy factor (if “No”), at step 1068 the method 1050 includes generating a revised design setpoint of the variable load by increasing the design flow by a flow increment (e.g. by 10% increments calculated from the original design flow for each iteration), at the same design head. The method 1050 then iterates and proceeds to step 1054 with the higher design flow rate, e.g. determining a design setpoint of the variable load comprising design head and design flow with the 10% higher design flow. Steps 1056 onwards then proceed with the N candidate variable control pumps in parallel operating at the 10% higher design flow, and calculating redundancy for N-1 control pumps. The method 1050 iterates until the answer to step 1064 is “Yes”.

[0344] In an example, the present iteration also stops when the cost (e.g. LCC) of the present iteration is higher than the cost of a previous iteration. Example cost calculations are detailed in relation to at least the method 1000 of Figure 10A.

[0345] The method 1050 can include generating output for configuring the one candidate variable control pump with the first respective control curve at the headsetpoint and the flow setpoint (e.g., the last-noted flow setpoint from the above-noted iterations at step 1068), and a second respective control curve which includes a second design setpoint at the respective maximum design flow capacity at the head setpoint. The output can include program instructions for configuring the one candidate variable control pump, a message, or a user output interface.

[0346] An example embodiment is a method for a variable load, the method being performed by at least one processor and comprising:a) determining a threshold redundancy factor;b) determining a design setpoint of the variable load comprising design head and design flow;c) determining N candidate variable control pumps in parallel to fulfill the variable load based on the design setpoint, wherein N is at least 2;d) calculating, for operating N-1 of the candidate variable control pumps at a head setpoint, a respective maximum flow capacity of each of the N-1 of the candidate variable control pumps;e) calculating a total maximum flow capacity at the head setpoint using the respective maximum flow capacity of the N-1 of the candidate variable control pumps;f) calculating a redundancy factor based on the design flow and the total maximum flow capacity at the head setpoint based on the respective maximum flow capacity of the N-1 of the candidate variable control pumps;g) determining whether the redundancy factor exceeds the threshold redundancy factor; andh) selecting, when the redundancy factor exceeds the threshold redundancy factor, the N candidate variable control pumps to source the variable load.

[0347] In an example, the method further includes: determining that the redundancy factor is below the threshold redundancy factor, and in response to said determining: b’) generating a revised design setpoint of the variable load by increasing the design flow of the design setpoint by a flow increment; performing steps c) to g) withthe revised design setpoint; iterating steps b’) and c) to g) with the revised design setpoint; and ending the iterating when the redundancy factor exceeds the threshold redundancy factor.

[0348] In an example, the flow increment is 10% of the design flow.

[0349] In an example, the method further includes: determining a cost of the N candidate variable control pumps over a time period, and performing the ending of the iterating when the cost is higher than a previous iteration.

[0350] In an example, the method further includes: generating output for configuring the N candidate variable control pumps with a respective control curve for the design setpoint and a second respective control curve for the respective maximum flow capacity at the head setpoint.

[0351] In an example, the method further includes: determining a load profile of the variable load; and determining a cost of the N candidate variable control pumps using the load profile and a respective control curve of the N candidate variable control pumps for the design setpoint.

[0352] In an example, the cost includes a life cycle cost.

[0353] In an example, the method further includes: generating for output the N candidate variable control pumps, the cost, and the redundancy factor.

[0354] In an example, the method further includes: determining one candidate variable control pump to fulfill the variable load using the design setpoint; and calculating a second cost of the one candidate variable control pump to fulfill the variable load using the load profile and a second respective control curve of the one candidate variable control pump for the design setpoint, wherein the generating for output includes the one candidate variable control pump and the second cost.

[0355] In an example, the generating for output includes respective parallel operation pump curves for all of 1 to the N candidate variable control pumps.

[0356] In an example, the head setpoint is the design head.

[0357] In an example, the head setpoint is maximum system head for the N-1 of the candidate variable control pumps.

[0358] In an example, the calculating the redundancy factor comprises calculating:, > % Redundancy

[0359] In an example, the threshold redundancy factor is at least 100%, or at least 85%, or at least 70%.

[0360] In an example, the method further includes: determining a building type of the variable load, wherein the determining the threshold redundancy factor is based on the building type.

[0361] In an example, the threshold redundancy factor is: at least 100% when the building type is labelled as mission critical; at least 85% when the building type is labelled as highly comfort sensitive; or at least 70% when the building type is labelled as generic.

[0362] In an example, the threshold redundancy factor is: at least 100% when the building type is a data center, critical care, blood bank, laboratory, research and development center, or hospital; at least 85% when the building type is a university campus, commercial, hotel, office, mixed use, or outpatient center; or at least 70% when the building type is a school, an apartment, a condominium, a religious institution, a factory, or a warehouse.

[0363] In an example, the method further includes operating the N candidate variable control pumps to source the variable load.

[0364] In an example, at least two of the N candidate variable control pumps are in a multiple pump unit.

[0365] Referring to Figure 11 A, examples of the output from the software (or method) is now described in greater detail. The graphical user interface is generated from the equipment (control pumps) that was selected by the processor and / or the user. The output can include program instructions for configuring the N candidate variable control pumps at the first respective design setpoint and the second respective design setpoint.

[0366] Comparative data is detailed on user specification I traditional selection, supplier solution(s), and supplier system solution. The user can click on the lower right corner of the item of interest which opens the details for inspection. This includes:

[0367] 1 ) Selection rankings to allow any changes required (e.g. up to 4).

[0368] 2) Single and parallel curves.

[0369] 3) Drawings and options.

[0370] 4) Return to selection available for tweaks or reselection due to new info. All identification data is retained with the new selection, etc.

[0371] Up-front data can include:

[0372] 1 ) Designed for anonymous user and user discipline, if known.

[0373] 2) First Installed cost, including product pricing and ratio to other items.

[0374] 3) Operating costs with ratios to other selections.

[0375] 4) Product pricing ratios.

[0376] 5) A “payback” button is available on the best solution output display and links with the data in an energy cost tab to compare the optimum selections against the default traditional offering or competitors' specifications.

[0377] If user discipline is known from the login, use the following display for the appropriate customer base:

[0378] 1 ) Engineer I Owner: 25-yr LCC ratio foremost, with first installed cost and pricing and operating cost ratios available to them on the ranking grid

[0379] 2) Mechanical Contractor - Pricing and first installed cost ratios foremost, with LCC cost and operating cost ratios available to them on the ranking grid

[0380] 3) Wholesales I OEM - Pricing ratios foremost, with installation and operating cost ratios available to them on the ranking grid.

[0381] Carbon emission statement is included on the user output screen along with the energy savings, such as:

[0382] 1) GHG / Carbon Reduction (Tonnes CO2 Emissions / Year). Can include representative High, Medium and Low grid emission factors for locations in Canada and the USA. Coal power generation is predominant in grids with High emission factors and natural gas, nuclear and / or hydro are predominant in grids with Low emission factors.

[0383] 2) Value articulation letter is to be available to users. An example of the value articulation letter with appendices is illustrated in Figures 11 B-11 D.

[0384] Examples of the ranking of the output from the software (or method) is now described in greater detail.

[0385] The ranking for the customer display can be based on the lowest Installed Cost, which includes the customer specified product, a supplier’s equal to the customer product, redundancy selection, with parallel and intelligent software as appropriate. The output display can show the solutions in order.

[0386] An example exception is in the event two selections are ranked equal, where the equipment with lower installed motor power an rank higher.

[0387] Ranking for contractors display can rank selections by lowest installed cost estimates and lowest pricing, each for the various total results for the selected equipment. Operating and LCC cost ratios can also be detailed on the selection grid.

[0388] Building owners and consultants display can rank selections by lowest 25-year LCC. Operating costs, including maintenance estimates and pricing can also be detailed on the selection grid.

[0389] Wholesaler and OEM login ranks selections by lowest pricing ratio for the various total results for the selected equipment. First installed cost and operating cost ratios is also detailed on the selection grid.

[0390] Another example embodiment is a system, comprising the at least one processor for performing the method of any one of the above.

[0391] Another example embodiment is a non-transitory computer readable medium having instructions stored thereon executable by at least one processor for performing the method of any one of the above.

[0392] 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.

[0393] 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.

[0394] 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.

[0395] In example embodiments, the one or more controllers can be implemented by or executed by, for example, one or more of the following systems: PersonalComputer (PC), Programmable Logic Controller (PLC), Microprocessor, Internet, Cloud Computing, Mainframe (local or remote), mobile phone or mobile communication device.

[0396] 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.

[0397] 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 will be 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 subcombination 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.

[0398] 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

1. WHAT IS CLAIMED IS:

1. A method for 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 comprising design head and design flow;determining N candidate variable control pumps in parallel to fulfill the variable load based on the design setpoint, wherein N is at least 2;calculating a first cost over a time period of operating the N candidate variable control pumps to fulfill the variable load using the load profile and a first respective control curve of the N candidate variable control pumps for the design setpoint;calculating a total maximum flow capacity at a head setpoint of N-1 of the candidate variable control pumps;calculating a redundancy factor based on the design flow and the total maximum flow capacity at the head setpoint of the N-1 of the candidate variable control pumps; andgenerating for output the N candidate variable control pumps, the first cost, and the redundancy factor.

2. The method as claimed in claim 1 , further comprising:determining one candidate variable control pump to fulfill the variable load using the design setpoint; andcalculating a second cost of the one candidate variable control pump to fulfill the variable load using the load profile and a second respective control curve of the one candidate variable control pump for the design setpoint,wherein the generating for output includes the one candidate variable controlpump and the second cost.

3. The method as claimed in claim 2, wherein the determining the one candidate variable control pump comprises selecting the one candidate variable control pump that fulfills the design setpoint which has a lowest first installed cost.

4. The method as claimed in claim 2, further comprising selecting the N candidate variable control pumps which have a lowest differential cost from the second cost to the first cost.

5. The method as claimed in claim 2, wherein the generating for output includes generating output for configuring the one candidate variable control pump with the first respective control curve and the second respective control curve.

6. The method as claimed in claim 1 , wherein the generating for output includes respective parallel operation pump curves for all of 1 to the N candidate variable control pumps.

7. The method as claimed in claim 1 , wherein the head setpoint is the design head.

8. The method as claimed in claim 1 , wherein the head setpoint is maximum system head for the N-1 of the candidate variable control pumps.

9. The method as claimed in claim 1 , wherein the calculating the redundancy factor comprises calculating:_ . > , , >% Redundancy10. The method as claimed in claim 1, further comprising selecting the N candidate variable control pumps which have the first cost which is lowest.

11. The method as claimed in claim 1 , wherein the first cost includes a life cycle cost.

12. The method as claimed in claim 1 , further comprising:iterating, by increasing a pump capability, increasing a number of the N candidatevariable control pumps, and / or increasing a pump number per multi-pump unit: the determining the N candidate variable control pumps in parallel and the calculating the first cost until the first cost reaches a local minimum.

13. The method as claimed in claim 12, wherein the pump capability includes casing size, motor power, and / or motor speed.

14. The method as claimed in claim 1 , further comprising:repeating the determining the N candidate variable control pumps in parallel and the calculating the first cost for different combinations of pump capability, number of the N candidate variable control pumps, and / or increasing a pump number per multi-pump unit.

15. The method as claimed in claim 14, wherein the pump capability includes casing size, motor power, and / or motor speed.

16. The method as claimed in claim 1 , wherein at least two of the N candidate variable control pumps are in a multiple pump unit.

17. The method as claimed in claim 1 , further comprising selecting or receiving selection of the N candidate variable control pumps for installation to source the variable load.

18. The method as claimed in claim 1, further comprising operating the N candidate variable control pumps to source the variable load.

19. The method as claimed in claim 1 , further comprising:determining a threshold redundancy factor;determining whether the redundancy factor exceeds the threshold redundancy factor; andselecting, when the redundancy factor exceeds the threshold redundancy factor, the N candidate variable control pumps to source the variable load.

20. The method as claimed in claim 19, further comprising determining a building type of the variable load, wherein the determining the threshold redundancy factor is based on the building type.

21. The method as claimed in claim 20, wherein the threshold redundancy factor is at least 100%, at least 85%, or at least 70%.

22. The method as claimed in claim 20, wherein the threshold redundancy factor is:at least 100% when the building type is labelled as mission critical;at least 85% when the building type is labelled as highly comfort sensitive; or at least 70% when the building type is labelled as generic.

23. The method as claimed in claim 20, wherein the threshold redundancy factor is:at least 100% when the building type is a data center, critical care, blood bank, laboratory, research and development center, or hospital;at least 85% when the building type is a university campus, commercial, hotel, office, mixed use, or outpatient center; orat least 70% when the building type is a school, an apartment, a condominium, a religious institution, a factory, or a warehouse.

24. The method as claimed in claim 1 , wherein the generating for output includes generating output for configuring the N candidate variable control pump with the first respective control curve and a second respective control curve which includes the total maximum flow capacity at the head setpoint.

25. A method for a variable load, the method being performed by at least one processor and comprising:a) determining a threshold redundancy factor;b) determining a design setpoint of the variable load comprising design head and design flow;c) determining N candidate variable control pumps in parallel to fulfill the variable load based on the design setpoint, wherein N is at least 2;d) calculating, for operating N-1 of the candidate variable control pumps at a head setpoint, a respective maximum flow capacity of each of the N-1 of the candidate variable control pumps;e) calculating a total maximum flow capacity at the head setpoint using the respective maximum flow capacity of the N-1 of the candidate variable control pumps;f) calculating a redundancy factor based on the design flow and the total maximum flow capacity at the head setpoint based on the respective maximum flow capacity of the N-1 of the candidate variable control pumps;g) determining whether the redundancy factor exceeds the threshold redundancy factor; andh) selecting, when the redundancy factor exceeds the threshold redundancy factor, the N candidate variable control pumps to source the variable load.

26. The method as claimed in claim 25, further comprising:determining that the redundancy factor is below the threshold redundancy factor, and in response to said determining:b’) generating a revised design setpoint of the variable load by increasing the design flow of the design setpoint by a flow increment;performing steps c) to g) with the revised design setpoint;iterating steps b’) and c) to g) with the revised design setpoint; andending the iterating when the redundancy factor exceeds the threshold redundancy factor.

27. The method as claimed in claim 26, wherein the flow increment is 10% of the design flow.

28. The method as claimed in claim 26, further comprising determining a cost of the N candidate variable control pumps over a time period, and performing the ending of the iterating when the cost is higher than a previous iteration.

29. The method as claimed in claim 26, further comprising generating output for configuring the N candidate variable control pumps with a respective control curve for the design setpoint and a second respective control curve for the respective maximum flow capacity at the head setpoint.

30. The method as claimed in claim 25, further comprising:determining a load profile of the variable load; anddetermining a cost of the N candidate variable control pumps using the load profile and a respective control curve of the N candidate variable control pumps for the design setpoint.

31. The method as claimed in claim 30, wherein the cost includes a life cycle cost.

32. The method as claimed in claim 30, further comprising generating for output the N candidate variable control pumps, the cost, and the redundancy factor.

33. The method as claimed in claim 32, further comprising:determining one candidate variable control pump to fulfill the variable load using the design setpoint; andcalculating a second cost of the one candidate variable control pump to fulfill the variable load using the load profile and a second respective control curve of the one candidate variable control pump for the design setpoint,wherein the generating for output includes the one candidate variable control pump and the second cost.

34. The method as claimed in claim 32, wherein the generating for output includes respective parallel operation pump curves for all of 1 to the N candidate variable controlpumps.

35. The method as claimed in claim 25, wherein the head setpoint is the design head.

36. The method as claimed in claim 25, wherein the head setpoint is maximum system head for the N-1 of the candidate variable control pumps.

37. The method as claimed in claim 25, wherein the calculating the redundancy factor comprises calculating:% Redundancy38. The method as claimed in claim 25, wherein the threshold redundancy factor is at least 100%, or at least 85%, or at least 70%.

39. The method as claimed in claim 25, further comprising determining a building type of the variable load, wherein the determining the threshold redundancy factor is based on the building type.

40. The method as claimed in claim 39, wherein the threshold redundancy factor is:at least 100% when the building type is labelled as mission critical;at least 85% when the building type is labelled as highly comfort sensitive; or at least 70% when the building type is labelled as generic.

41. The method as claimed in claim 39, wherein the threshold redundancy factor is:at least 100% when the building type is a data center, critical care, blood bank, laboratory, research and development center, or hospital;at least 85% when the building type is a university campus, commercial, hotel, office, mixed use, or outpatient center; orat least 70% when the building type is a school, an apartment, a condominium, areligious institution, a factory, or a warehouse.

42. The method as claimed in claim 25, further comprising operating the N candidate variable control pumps to source the variable load.

43. The method as claimed in claim 25, wherein at least two of the N candidate variable control pumps are in a multiple pump unit.

44. A method for controlling a variable control pump installed with at least one other variable control pump in parallel to source a variable load, the method being performed by at least one processor and comprising:operating the variable control pump on a first control curve which includes a design setpoint of the variable load comprising design head and design flow;determining that one of the other variable control pumps is unavailable; andoperating, when the one of the other variable control pumps is unavailable, the variable control pump on a second control curve which includes a second design setpoint at maximum flow capacity at a head setpoint.

45. The method as claimed in claim 44, wherein the first control curve is a quadratic control curve from the design setpoint to a minimum head value, and wherein the second control curve is a second quadratic control curve from the second design setpoint to the minimum head value.

46. The method as claimed in claim 45, wherein the variable control pump includes an internal power sensor for detecting internal motor power and an internal speed sensor for detecting internal motor speed, wherein the processor is configured to map the internal motor power and the internal motor speed to head and flow.

47. The method as claimed in claim 46, wherein the first control curve is a quadratic control curve from the design setpoint to a minimum head value, and wherein the second control curve is a second quadratic control curve from the second design setpoint to the minimum head value.

48. The method as claimed in claim 47, wherein the minimum head value is on or about 40% of the design head.

49. The method as claimed in claim 44, wherein the head setpoint is maximum system head for (N-1) pumps, wherein N is a total number of pumps including the variable control pump and the at least one other variable control pump, wherein the (N-1) pumps is N minus the one of the other variable control pumps that is unavailable.

50. The method as claimed in claim 44, wherein the head setpoint is the design head.

51. The method as claimed in claim 44, wherein the maximum flow capacity is limited by motor speed and / or motor power of the variable control pump.

52. The method as claimed in claim 44, wherein the variable control pump is a sensorless control pump that operates on the first control curve and the second control curve using at least one self-detected device property without an external sensor.

53. The method as claimed in claim 44, wherein the determining that the one of the other variable control pumps is unavailable comprises receiving a message.

54. The method as claimed in claim 44, wherein the variable control pump and the one of the other variable control pumps that is unavailable are part of a multiple pump unit.

55. The method as claimed in claim 44, wherein at least the operating the variable control pump on the second control curve provides redundancy for the one of the other variable control pumps that is unavailable.

56. The method as claimed in claim 44, wherein at least the operating the variable control pump on the second control curve satisfies a redundancy factor that exceeds a threshold redundancy factor.

57. The method as claimed in claim 56, wherein the calculating the redundancy factor is calculated as:% Redundancy 100;wherein:N is a total number of pumps including the variable control pump and the at least one other variable control pump;(N - 1 )Pumps is N minus the one of the other variable control pumps that is unavailable; andthe total maximum flow capacity is for the (N-1)PumpSat the head setpoint.

58. The method as claimed in claim 56, wherein the threshold redundancy factor is based on a building type of the variable load.

59. The method as claimed in claim 58, wherein the threshold redundancy factor is:at least 100% when the building type is labelled as mission critical;at least 85% when the building type is labelled as highly comfort sensitive; orat least 70% when the building type is labelled as generic.

60. The method as claimed in claim 58, wherein the threshold redundancy factor is:at least 100% when the building type is a data center, critical care, blood bank, laboratory, research and development center, or hospital;at least 85% when the building type is a university campus, commercial, hotel, office, mixed use, or outpatient center; orat least 70% when the building type is a school, an apartment, a condominium, a religious institution, a factory, or a warehouse.

61. A system, comprising the at least one processor for performing the method of any one of claims 1-60.

62. A non-transitory computer readable medium having instructions stored thereon executable by the at least one processor for performing the method as claimed in anyone of claims 1-60.

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