Automatic pressure maintenance installations in modern heating systems. Aupd selection for heating and cooling systems of high-rise buildings Frequency regulation per pump SPL® WRP-B(BL)
Pressure maintenance plant- This is a special system that is used to maintain a constant heat supply at various facilities. Today, such devices can be found on a variety of objects. These can be administrative buildings, and residential buildings, and shopping malls, and production shops. The main task of such automatic device is to maintain a stable pressure level. These devices are compatible with closed systems heating and water supply.
Devices can be equipped with powerful recharge units. In this case, the power of the equipment also increases. Since the material of the membranes is able to work exclusively in a certain temperature range. Accordingly, devices are best connected at those points where the temperature of the coolant does not exceed a certain indicator. If we talk about butyl tanks, it is recommended to install them on the return line heating system. If the temperature is higher, expansion tank connected using a series-connected intermediate tank. The pressure maintenance installation requires proper installation.
The installation consists of the following elements:
- expansion tank (or tank system);
- control valves;
- electronic devices.
Principle of operation.
Thanks to the unique membrane, pressure equalization is ensured between water and air, which are in the storage tank. In case of very low pressure, the compressor starts to pump air. thus, if too high pressure air begins to escape through a specialized solenoid valve. This principle of operation has been tested by time. There is no doubt about its reliability. Leading manufacturers give preference to him. This once again proves the many advantages of the principle. Many manufacturers, in order to retain air in the tank and prevent it from dissolving in water, the manufacturer separates the air and air chambers with a specialized butylene membrane.
Pressure maintenance plant modern model able to work smoothly even in a small area. In some systems, the unit is mounted on the side or top of the expansion tank, on the console. As a result, it provides high level efficiency in the smallest space.
Modular principle - providing special features.
As a rule, the modular principle applies to equipment that has a capacity of up to 24 MW. In this case, a compressor and the required number of additional tanks, which are necessary for the full operation of the system, are mounted next to the main tank.
Automation of the installation.
The pressure maintenance plant can be fully automated. In this case, the device is equipped with an automatic controlled make-up. Charging is carried out depending on the amount of water in the main tank. In this case, the simultaneous use of different vacuum units is possible. Thanks to this approach, the need for airing in the most high points systems.
Pressure maintenance installation - advantages of use.
The advantages of using the device include the following features:
- the pressure in the system is maintained by a slight fluctuation;
- if necessary, the device carries out automatic feeding;
- the system independently performs deaeration of the water in the system;
- lack of air even in the most top point system is guaranteed;
- there is no need to purchase expensive air vents and manual deaeration.
In addition to the above advantages, one can also note the silent operation of modern installations. When working on full power the equipment functions reliably. The loop water has virtually no air. This feature guarantees the absence of corrosion, erosion. Moreover, the system is less polluted, wears out, and better circulation is provided in the system. Improving heat transfer is ensured by the fact that there is no boiling boiler on the heat exchanger. Compared to membrane tanks, the pressure maintenance system is small in size.
The low noise level during operation allows the devices to be installed in rooms with high demands to soundproofing. The mode of operation of such a system is fully automated. Thus, the installation can be integrated into any modern system, which is characterized by structural complexity. A special anti-corrosion agent is applied to the surface that comes into contact with water. Any modern pressure maintenance installation complies with existing sanitary requirements.
Power and other performance indicators of the system.
The pressure maintenance installation can have a wide variety of capacities. Naturally, with an increase in power, the volume of the tank increases. This feature is explained by the fact that a large volume of capacity can compensate for expansion. At the same time, the ratio of the total volume of tanks to the expansion volume of the coolant also increases.
SPL® booster units are designed for pumping and boosting water pressure in domestic and industrial water supply systems of various buildings and structures, as well as in fire extinguishing systems.
This is a modular high-tech equipment consisting of a pump unit, including all the necessary piping, as well as a modern control system that guarantees energy-efficient and reliable operation, with all the necessary permits.
The use of components from leading world manufacturers, taking into account Russian standards, norms and requirements.
SPL® WRP: Symbol structure
SPL® WRP: composition of the pumping unit
Frequency control for all SPL® WRP-A pumps
The frequency control system for all pumps is designed to control and control standard asynchronous electric motors of pumps of the same size in accordance with external control signals. This system control provides the ability to control from one to six pumps.
The principle of operation of frequency control for all pumps:
1. The controller starts the frequency converter by changing the speed of the pump motor according to the readings of the pressure sensor based on PID control;
2. at the beginning of work, one variable frequency pump is always started;
3. The performance of the booster plant varies depending on the consumption by turning on / off the required number of pumps and parallel adjustment of the pumps in operation.
4. if the set pressure is not reached, and one pump is running at maximum frequency, then after a certain period of time the controller will turn on the additional frequency converter in operation, and the pumps will be synchronized in speed (pumps in operation operate at the same speed).
And so on until the pressure in the system reaches the set value.
When the set pressure value is reached, the controller will start to reduce the frequency of all running frequency converters. If during a certain time the frequency of the converters is kept below the set threshold, the additional pumps will be switched off one by one at certain intervals.
To equalize the resource of the electric motors of the pumps in time, the function of changing the sequence of switching on and off the pumps is implemented. It also provides for automatic activation of standby pumps in case of failure of the workers. The choice of the number of working and standby pumps is made on the controller panel. Frequency converters, in addition to regulation, provide a smooth start of all electric motors, as they are connected directly to them, which makes it possible to avoid the use of additional soft starters, limit the starting currents of electric motors and increase the operating life of pumps by reducing dynamic overloads of actuators when starting and stopping electric motors.
For water supply systems, this means the absence of water hammer when starting and stopping additional pumps.
For each electric motor, the frequency converter allows you to implement:
1. speed control;
2. overload protection, braking;
3. mechanical load monitoring.
Monitoring of mechanical load.
This set of features allows you to avoid the use of additional equipment.
Frequency regulation per pump SPL® WRP-B(BL)
In the base of the pumping unit of the SPL® WRP-BL configuration, there can be only two pumps, and the control is implemented only according to the principle of the working-standby pump operation scheme, while the working pump is always involved in operation with a frequency converter.
Frequency regulation is the most effective method regulation of pump performance. The cascade principle of pump control implemented in this case using frequency regulation has already firmly established itself as a standard in water supply systems, since it provides serious energy savings and an increase in system functionality.
The principle of frequency regulation for one pump is based on the control of the frequency converter controller, changing the speed of one of the pumps, constantly comparing the reference value with the reading of the pressure sensor. In the event of a lack of performance of the operating pump, an additional pump will be activated upon a signal from the controller, and if an accident occurs, the backup pump will be activated.
The signal from the pressure sensor is compared with the set pressure in the controller. The mismatch between these signals sets the speed of the pump impeller. At the beginning of the operation, the main pump is selected based on the estimated minimum operating time.
The main pump is the pump that this moment powered by a frequency converter. Additional and standby pumps are connected directly to the mains supply or via a soft starter. In this control system, the choice of the number of working / standby pumps is provided from the touch screen of the controller. The frequency converter is connected to the main pump and starts working.
The variable speed pump always starts first. Upon reaching a certain speed of the pump impeller, associated with an increase in water flow in the system, the next pump is switched on. And so on until the pressure in the system reaches the set value.
To equalize the resource of electric motors in time, the function of changing the sequence of connecting electric motors to the frequency converter is implemented. It is possible to change the switching time user.
The frequency converter provides regulation and soft start only of the electric motor that is connected directly to it, the rest of the electric motors are started directly from the network.
When using electric motors with a power of 15 kW or more, it is recommended to start additional electric motors through soft starters to reduce starting currents, limit water hammer and increase shared resource pump.
Relay control SPL® WRP-C
The operation of the pumps is carried out by a signal from a pressure switch set to a certain value. The pumps are switched on directly from the mains and operate at full capacity.
The use of relay control in the control of pumping units provides:
1. maintaining the set parameters of the system;
2. cascade method of managing a group of pumps;
3. mutual redundancy of electric motors;
4. alignment of motor resources of electric motors.
In pumping units designed for two or more pumps, if the performance of the operating pumps is insufficient, an additional pump is switched on, which will also be activated in the event of an accident of one of the operating pumps.
The pump is stopped with a predetermined time delay by a signal from the pressure switch about reaching the predetermined pressure value.
If the relay does not detect a pressure drop within the next set time, the next pump is stopped and then in a cascade until all pumps stop.
The control cabinet of the pumping unit receives signals from the dry-running protection relay, which is installed on the suction pipeline, or from the float from the storage tank.
At their signal, in the absence of water, the control system will turn off the pumps, protecting them from destruction due to dry running.
Automatic activation of standby pumps is provided in case of failure of the working ones and the possibility to select the number of working and standby pumps.
In pumping units based on 3 pumps or more, it becomes possible to control from an analog 4-20 MA sensor.
When operating pressure boosting systems with relay pressure maintenance principle:
1. pumps are switched on directly, which leads to water hammer;
2. energy saving is minimal;
3. discrete regulation.
This is almost imperceptible when using small pumps up to 4 kW. As the power of the pumps increases, pressure surges when switching on and off become more and more noticeable.
To reduce pressure surges, you can organize the inclusion of pumps with a sequential opening of the damper or install an expansion tank.
The installation of soft starters allows you to completely remove the problem.
Starting current with direct connection is 6-7 times higher than the nominal one, while soft start is gentle for the motor and mechanism. At the same time, the starting current is 2-3 times higher than the nominal one, which can significantly reduce pump wear, avoid water hammer, and also reduce the load on the network during start-up.
Direct start is the main factor leading to premature aging of the insulation and overheating of the motor windings and, as a result, a decrease in its resource by several times. The actual life of the electric motor to a greater extent depends not on the operating time, but on the total number of starts.
| Name of product | Brand, model | Specifications | Quantity | Cost without VAT, rub. | Cost with VAT, rub. | Wholesale cost. from 10 pcs. in rubles without VAT | Wholesale cost. from 10 pcs. in rubles VAT included |
|---|---|---|---|---|---|---|---|
| SHKTO-NA 1.1 | HxWxD 1000*800*300, Modicon ТМ221 controller unit 40 inputs/outputs, 24VDC power supply, built-in Ethernet port, Magelis STU 665 operator panel, switching power supply Quint - PS/IAC/24DC/10/, unit uninterruptible power supply Quint - UPS / 24 / 24DC / 10, NSG-1820MC modem, analog module TMZ D18, galvanic isolation, circuit breakers and relays for a power of 1.1 kW | 1 | 722 343,59 | 866 812,31 | 686 226,41 | 823 471,69 | |
| Cabinet of controller and telecommunication equipment MEGATRON | SHKTO-NA 1.5 | HxWxD 1000*800*300, Modicon ТМ221 controller unit 40 inputs/outputs, 24VDC power supply, built-in Ethernet port, Magelis STU 665 operator panel, switching power supply unit Quint - PS/IAC/24DC/10/, uninterruptible power supply unit Quint - UPS/ 24/24DC/10, NSG-1820MC modem, TMZ D18 analog module, galvanic isolation, circuit breakers and relays for 1.5 kW | 1 | 722 343,59 | 866 812,31 | 686 226,41 | 823 471,69 |
| Cabinet of controller and telecommunication equipment MEGATRON | SHKTO-NA 2.2 | HxWxD 1000*800*300, Modicon ТМ221 controller unit 40 inputs/outputs, 24VDC power supply, built-in Ethernet port, Magelis STU 665 operator panel, switching power supply unit Quint - PS/IAC/24DC/10/, uninterruptible power supply unit Quint - UPS/ 24/24DC/10, NSG-1820MC modem, TMZ D18 analog module, galvanic isolation, circuit breakers and relays for 2.2 kW | 1 | 735 822,92 | 882 987,51 | 699 031,77 | 838 838,12 |
| Cabinet of controller and telecommunication equipment MEGATRON. | SHKTO-NA 3.0 | HxWxD 1000*800*300, Modicon ТМ221 controller unit 40 inputs/outputs, 24VDC power supply, built-in Ethernet port, Magelis STU 665 operator panel, switching power supply unit Quint - PS/IAC/24DC/10/, uninterruptible power supply unit Quint - UPS/ 24/24DC/10, NSG-1820MC modem, TMZ D18 analog module, galvanic isolation, circuit breakers and relays for 3.0 kW | 1 | 747 738,30 | 897 285,96 | 710 351,38 | 852 421,66 |
| Cabinet of controller and telecommunication equipment MEGATRON | SHKTO-NA 4.0 | HxWxD 1000*800*300, Modicon ТМ221 controller unit 40 inputs/outputs, 24VDC power supply, built-in Ethernet port, Magelis STU 665 operator panel, switching power supply unit Quint - PS/IAC/24DC/10/, uninterruptible power supply unit Quint - UPS/ 24/24DC/10, NSG-1820MC modem, TMZ D18 analog module, galvanic isolation, circuit breakers and relays for 4.0 kW | 1 | 758 806,72 | 910 568,06 | 720 866,38 | 865 039,66 |
| Cabinet of controller and telecommunication equipment MEGATRON | SHKTO-NA 7.5 | HxWxD 1000*800*300, Modicon ТМ221 controller unit 40 inputs/outputs, 24VDC power supply, built-in Ethernet port, Magelis STU 665 operator panel, switching power supply unit Quint - PS/IAC/24DC/10/, uninterruptible power supply unit Quint - UPS/ 24/24DC/10, NSG-1820MC modem, TMZ D18 analog module, galvanic isolation, circuit breakers and relays for 7.5 kW | 1 | 773 840,78 | 928 608,94 | 735 148,74 | 882 178,48 |
| Cabinet of controller and telecommunication equipment MEGATRON | SHKTO-NA 15 | HxWxD 1000*800*300, Modicon ТМ221 controller unit 40 inputs/outputs, 24VDC power supply, built-in Ethernet port, Magelis STU 665 operator panel, switching power supply unit Quint - PS/IAC/24DC/10/, uninterruptible power supply unit Quint - UPS/ 24/24DC/10, NSG-1820MC modem, TMZ D18 analog module, galvanic isolation, circuit breakers and relays for 15 kW | 1 | 812 550,47 | 975 060,57 | 771 922,94 | 926 307,53 |
| Cabinet of controller and telecommunication equipment MEGATRON | SHPch | HxWxD 500x400x210 with mounting plate, frequency converter ACS310-03X 34A1-4, circuit breaker | 1 | 40 267,10 | 48 320,52 | 38 294,01 | 45 952,81 |
| № | Name of product | Brand, model | Specifications | Retail price in rubles without VAT | Wholesale price from 10 pcs. in rubles without VAT | Wholesale price from 10 pcs. in rubles VAT included |
|---|---|---|---|---|---|---|
| 1 | SPL WRP-S 2 CR10-3 X-F-A-E | 714 895,78 | 681 295,67 | 817 554,81 | ||
| Nominal flow 10 m3, nominal head 23.1 m, power 1.1 kW. The station is equipped with an automatic pressure support system with the ability to provide remote control and control of pump operation, pressure sensors, dry running sensor, intake and pressure manifolds, check valves, shut-off gates. | ||||||
| 2 | Pumping station for boosting pressure based on grundfos pumps | SPL WRP-S 2 CR15-3 X-F-A-E | 968 546,77 | 923 025,07 | 1 107 630,08 | |
| Nominal flow 17 m3, nominal head 33.2 m, power 3 kW. The station is equipped with a pressure support automation system with the ability to provide remote monitoring and control of the operation of pumps, pressure sensors, a dry running sensor, intake and pressure manifolds, check valves, shut-off gates. | ||||||
| 3 | Pumping station for boosting pressure based on grundfos pumps | SPL WRP-S 2 CR20-3 X-F-A-E | 1 049 115,42 | 999 806,99 | 1 199 768,39 | |
| rated flow 21 m3, rated head 34.6 m, power 4 kW. the station is equipped with an automatic pressure support system with the ability to provide remote monitoring and control of the operation of pumps, pressure sensors, a dry running sensor, intake and pressure manifolds, check valves, shut-off gates. | ||||||
| 4 | Pumping station for boosting pressure based on grundfos pumps | SPL WRP-S 2 CR5-9 X-F-A-E | 683 021,93 | 650 919,89 | 781 103,87 | |
| nominal flow 5.8 cubic meters, nominal head 42.2 m power 1.5 kW the station is equipped with an automatic pressure support system with the ability to provide remote control and management of the operation of pumps, pressure sensors, a dry running sensor, intake and pressure manifolds, check valves, shut-off gates. | ||||||
| 5 | Pumping station for boosting pressure based on grundfos pumps | SPL WRP-S 2 CR45-4-2 X-F-A-E | 2 149 253,63 | 2 048 238,70 | 2 457 886,45 | |
| rated flow 45 m.cub.h., rated head 72.1 m power 15 kW the station is equipped with an automatic pressure support system with the ability to provide remote control and management of the operation of pumps, pressure sensors, a dry running sensor, intake and pressure manifolds, check valves, shut-off shutters. | ||||||
| 6 | Pumping station for boosting pressure based on grundfos pumps | SPL WRP-S 2 CR45-1-1 X-F-A-E | 1 424 391,82 | 1 357 445,40 | 1 628 934,48 | |
| rated flow 45 m.cub.h., rated head 15m power 3 kW the station is equipped with an automatic pressure support system with the ability to provide remote control and management of the operation of pumps, pressure sensors, a dry running sensor, intake and pressure manifolds, check valves, shut-off gates. | ||||||
| 7 | Pumping station for boosting pressure based on grundfos pumps | SPL WRP-S 2 CR5-13 X-F-A-E | 863 574,18 | 822 986,19 | 987 583,43 | |
| rated flow 5.8 m3, rated head 66.1 m, power 2.2 kW. the station is equipped with an automatic pressure support system with the ability to provide remote monitoring and control of the operation of pumps, pressure sensors, a dry running sensor, intake and pressure manifolds, check valves, shut-off gates. | ||||||
| 8 | Pumping station for boosting pressure based on grundfos pumps | SPL WRP-S 2 CR64-3-2 X-F-A-E | 2 125 589,28 | 2 025 686,58 | 2 430 823,90 | |
| nominal flow 64 m3, nominal head 52.8 m, power 15 kW. the station is equipped with an automatic pressure support system with the ability to provide remote monitoring and control of the operation of pumps, pressure sensors, a dry running sensor, intake and pressure manifolds, check valves, shut-off gates. | ||||||
| 9 | Pumping station for boosting pressure based on grundfos pumps | SPL WRP-S 2 CR150-1 X-F-A-E | 2 339 265,52 | 2 226 980,77 | 2 672 376,93 | |
| Nominal flow 150 m3, nominal head 18.8 m, power 15 kW. The station is equipped with a pressure support automation system with the ability to provide remote monitoring and control of the operation of pumps, pressure sensors, a dry running sensor, intake and pressure manifolds, check valves, shut-off gates. | ||||||
Pressure maintenance installations (UPD, AUPD, pressure and expansion machines) are complex technical systems designed to maintain pressure in heating and cooling circuits. Especially this equipment has become in demand in our country in last years in connection with the growth of high-rise construction, caused by the processes of urbanization. Pump and compressor automatic pressure maintenance units FLAMCO replace traditional expansion tanks in heating and cooling systems in all operating pressure and temperature ranges.
The main advantage of UPD of all manufacturers (Flamco, etc.) is the increased utilization factor of storage tanks (about 0.9). When pumping units excess coolant is in non-pressure tanks. To maintain the pressure in the system at the required level, the coolant is either added to the system by a pump (pumps) or discharged into the storage tank through valves with electro-motor drives. Compressor AUPDs are essentially modified traditional membrane expansion tanks, the pressure in which is controlled by a compressor and relief valves controlled by automation.
The use of AUPD Flamco instead of membrane expansion tanks allows you to quickly install operating pressure in heating and cooling systems in a wide range. When using conventional diaphragm tanks, to change the operating pressure in the system, it is necessary to empty the tank and adjust the pressure in it. The same procedure must be carried out for each maintenance boiler room.
All Flamco pressure maintenance units are equipped with a reliable power electrical part and unique microprocessor control with LCD display. The original automation SPCx-lw(hw) has several levels of access, allowing you to reliably protect the settings from outside interference. A backup copy of the system settings can be saved to an SD card by our specialist during commissioning. Automation has the ability to remotely control the operation. This function is quite simple to implement, unlike AUPDs from other manufacturers.
All Flamco compressors and pumps are equipped with intelligent make-up control. In pumping AUPDs, there is make-up going through a storage tank, in compressor rooms - directly to the heating (cold supply) system.
The Flamco pump pressure regulators - Flamcomat - are equipped with an intelligent system degassing function that allows minimizing the gas content in the coolant and, accordingly, significantly reducing the corrosion load on pipelines, heating appliances, heat exchangers and boiler units.
Many years of experience in the design and operation of high-rise buildings allows us to formulate the following conclusion: the basis for the reliability and efficiency of the heating system as a whole is compliance with the following technical requirements:
- The constancy of the coolant pressure in all modes of operation.
- permanence chemical composition coolant.
- Absence of gases in free and dissolved form.
Failure to meet at least one of these requirements leads to increased wear of heat engineering equipment (radiators, valves, thermostats, etc.). In addition, the consumption of thermal energy increases, and, accordingly, material costs increase. To ensure the fulfillment of these requirements, installations for maintaining pressure, automatic make-up and removal of gases, for example, the Eder company, the main supplier of which for Russian market for more than 10 years has been Hertz Armaturen ».
Eder equipment consists of separate modules that provide pressure maintenance, make-up and degassing of the coolant. Coolant pressure maintenance module A consists of an expansion tank 1, in which an elastic chamber 2 is located, which prevents the coolant from contacting with air and directly with the tank walls, which distinguishes Eder expansion units from membrane-type expanders, in which the tank walls are subject to corrosion due to for contact with water.
With an increase in pressure in the system, caused by the expansion of water during heating, valve 3 opens, and excess water from the system enters the expansion tank. When cooling and, accordingly, the volume of water in the system decreases, pressure sensor 4 is activated, which includes pump 5, which pumps the coolant from the tank into the system until the pressure in the system becomes equal to the specified one.
Make-up module B allows you to compensate for the loss of coolant in the system resulting from different kind leaks. When the water level in tank 1 decreases and the specified minimum value is reached, valve 6 opens and water from the cold water supply system enters the expansion tank. When the level set by the user is reached, the valve turns off and the make-up stops.
During the operation of heating systems in high-rise buildings, the most acute issue is the degassing of the coolant. Existing air vents allow you to get rid of the “airiness” of the system, but do not solve the problem of water purification from gases dissolved in it, primarily atomic oxygen and hydrogen, which cause not only corrosion, but also cavitation at high speeds and pressures of the coolant, which destroys the system devices: pumps , valves and fittings.
When using modern aluminum radiators at the expense chemical reaction hydrogen is formed in the water, the accumulation of which can lead to a rupture of the radiator housing, with all the “consequences” that follow from it. Eder’s degassing module C uses physical way continuous removal of dissolved gases due to a sharp decrease in pressure.
When the valve 9 is briefly opened in a given volume (approx. 200 l) 8 within a fraction of a second, the water pressure exceeding 5 bar drops to atmospheric pressure. In this case, there is a sharp release of gases dissolved in water (the effect of opening a bottle of champagne). A mixture of water and gas bubbles is fed into the expansion tank 1. The degassing tank 8 is replenished from the expansion tank 1 with water that has already been degassed.
Gradually, the entire volume of the coolant in the system will be completely cleaned of impurities and gases. The higher the static height of the heating system, the higher the requirements for degassing and constant pressure of the heat carrier. All these modules are controlled microprocessor unit D, having diagnostic functions and the possibility of inclusion in the automated systems dispatching.
The use of Eder installations is not limited to high-rise buildings. It is advisable to use them in buildings with an extensive heating system (sports facilities, supermarkets, etc.). Compact EAC units, in which an expansion vessel with a volume of up to 500 l is articulated with a control cabinet, can be successfully used as an addition to autonomous heating systems in individual construction. Eder installations, successfully operating in all high-rise buildings in Germany, are a choice in favor of modern engineering system heating.
