HYDRONICS for PLUMBING ENGINEERS
By Roy C.E. Ahlgren
Parallel Pumps Again
In the November/December 2006 issue of PS&D, I discussed
using parallel pumps as a way of increasing reliability and
decreasing operating costs in hydronic systems. That article
finished with a short discussion of parallel pumps operating
together at variable speeds, with both pumps receiving the
same output from their variable-speed drives and operating at
the same revolutions per minute (rpm). Im sometimes asked
if it is possible to operate a constant-speed and variable-speed
pump together in parallel. Its an interesting idea that deserves
a closer look.
Often, the objective in using parallel constant- and variable-
speed pumps is to minimize the systems initial and operating
costs. For example, assume two pumps in parallel, each selected
for full system head and half of full flow. Initial cost is reduced
because only one variable-speed drive is needed; the constant-
speed pump needs only a standard motor starter. (The system
also requires a controller and sensor to provide automatic oper-
ation.)
Pump energy also is saved. In a variable-volume hydronic
system, the variable-speed pump handles part-load flows up to
its full rpm capability; the constant-speed pump is turned off.
If flow increases, the constant-speed pump stages on, and the
variable-speed pump slows to meet the actual flow require-
ment. As flow increases, the variable-speed pump again speeds
up to full rpm, so at design flow both pumps are operating at full
speed, splitting the flow between them.
It Sounds Like a Good Idea, but
Lets take a closer look at part load in an HVAC system, where
the variable-speed pump is making up the difference between
the constant-speed pumps capability and the required system
Figure 1 Constant-speed and variable-speed pumps in parallel
50 Plumbing Systems & Design JANUARY/FEBRUARY 2007
flow. The control curve represents the sum of friction head loss
and minimum control head to be maintained by the control
system at any flow. The minimum control head is the differen-
tial head maintained by the control system across a selected coil
and control valve. Its a good idea in HVAC systems to install the
differential pressure sensor at a coil that is located far from the
pump, so the minimum control head is a small fraction of the
total head required.
Point A in Figure 1 represents a requirement for 4,000 gallons
per minute (gpm) and 80 feet of head in a system that is designed
for 4,500 gpm at 100 feet of head. The variable-speed pump
cannot meet that point by itself, even running at full speed, so
the control system must turn on the constant-speed pump, also
at full speed. The two pumps together now operate at Point B,
providing more flow than necessary. The variable-speed pump
can be ordered to slow from full rpm to 1,550 rpm to meet the
current flow requirement. At 80 feet of head, the constant-speed
pump can provide only 2,900 gpm, so the variable-speed pump
must make up the difference, or 1,100 gpm. The variable-speed
pump could provide the 1,100 gpm by rotating at 900 rpm, but
it would develop only 25 feet of head at that speed. Unless the
control system maintains speed at 1,550 rpm, the variable-
speed pump will be deadheaded, and its check valve will be
held closed by the 80 feet of discharge pressure from the con-
stant-speed pump. At 900 rpm, the variable-speed pump would
contribute nothing to the system flow and eventually overheat.
The 1,100 gpm provided by the variable-speed pump rotat-
ing at 1,550 rpm is an artificially low flow compared to the head
being developed in the pump volute. It is likely that large, unbal-
anced pressures will exist in the pump volute, causing excessive
loads on the pump shaft and bearings. The shaft and bearings
are not fragile; they can withstand excessive
loads for some period, but they will start to
fail as the loads get higher for longer dura-
tions.
So, Should I Design My System This
Way?
In the early days of variable-speed pump-
ing, adjustable-frequency drives were much
more expensive than they are now, so this
kind of application made some sense. Today,
an adjustable-frequency drive and a large
motor starter cost nearly the same. The pri-
mary reason for using both a constant-speed
and variable-speed pump in parallel has
largely disappeared. Running both pumps
at the same variable speed reduces wear and
provides excellent energy savings at compa-
rable cost.
What About a Pressure Booster
System?
A variable-speed pressure booster pump
is usually controlled by sensing a single
PSDMAGAZINE.ORG
point pressure, preferably near the top of the plumbing system.
Compared to an HVAC system, the minimum control head is
greater; therefore, the control curve is flatter, and the range of
rpm variation in the variable-speed pump is smaller. A vari- Roy Ahlgren is director of the ITT Bell &
able-speed pump in such a system cannot slow as much as Gossett Little Red Schoolhouse (8200 N. Austin
Ave., Morton Grove, IL 60053). To comment
an HVAC pump can. For these reasons, constant-speed and on this article or for more information, e-mail
variable-speed pumps are sometimes operated in parallel by articles@psdmagazine.org.
a suitable control system.

WANTED
Technical Presentations for the
ASPE Technical Symposium
November 24, 2007
Atlanta, Georgia
Present an intensive two-, four-, or eight-hour
practical engineering and/or design seminar or interactive workshop.
The 2007 Symposium is designed to provide educational and professional development opportunities for plumbing
engineers and designers. The Technical Sympoisum Committee is looking for technical presentation proposals directed
to plumbing engineers and designers. Some technical proposal topic ideas include:
Green Buildings and Spaces Fire Protection
(e.g., green buildings, gray and black water reuse) Gas Systems (e.g., NOX, liquified, cryogenics)
Acoustics Plumbing Specifications
Seismic Design Drainage Systems
Venting Systems (e.g., gas, closed) Professional Development
Plumbing Systems for Specialized Facilities (e.g., time management, team development, business
(e.g., electronics, pharmaceuticals, health care) communications, negotiating, contracts)

PROPOSAL SUBMITTALS prepared to provide appropriate guidance and leadership.

Each proposal submittal should include a 200- to 350-word
abstract or description of the proposed seminar or workshop.
Information provided should include the following:
How the program will enhance the skills of the professional
plumbing engineer/designer
What practical or professional skills will be augmented and
strengthened
How the attendee to this session will benefit directly
What benefits this seminar will have for an attendees employer
Session level (beginner, intermediate, or professional)
Why a participant should attend this seminar/workshop
Handouts that will be incorporated into the seminar/workshop
Audio and visual media and materials that will be used
Presentations must be non-proprietary in nature as the
Technical Symposium is about learningnot selling. The
preferred technical session will be a minimum of two hours
in length (with breaks). Be sure your submittal provides
enough information to ensure the presentations will cover
a topic in detail and for the required time period.
PRESENTATION GUIDELINES
Presentations should include an introduction to the system(s)
under consideration, when appropriate; relevant terms and
definitions; formulas; applicable codes; and equipment
descriptions and specifications. Programs should include a
full discussion of the system design objectives and param-
eters, and should incorporate one or more realistic design
projects to be solved by the attendeespresenters should be
All programs should have relevant handout material that
includes all the information presented, incorporates copies
of all visual materials, and includes documentation of the
completed design project(s).
BIOGRAPHY
A one-page, 250-word biography for each instructor or pre-
senter should also be included (a photo is recommended)
with each proposal. Please be sure to include prior seminar
or presentation experience.
SUBMITTAL DATE
Proposals or a Statement of Intent to submit a proposal
should be received at the ASPE office no later than March
28, 2007.
SUBMIT WRITTEN PROPOSALS TO:
2007 ASPE Technical Symposium
c/o Stanley Wolfson, Executive Director
American Society of Plumbing Engineers
8614 W. Catalpa Avenue, Suite 1007
Chicago, IL 60656-1116
(773) 693-2773 Fax: (773) 695-9007 Email:
aspehq@aspe.org Internet: www.aspe.org
PROPOSALS MAY BE SUBMITTED ONLINE AT:|
www.aspe.org/Conv_Symp/cfp2007.html
(Note: Material submitted to ASPE for consideration will not be
returned.)

JANUARY/FEBRUARY 2007 Plumbing Systems & Design 51