COMMERCIAL BUILDING SERVICES

GRUNDFOS DISTRIBUTED PUMPING

PUMP SIZING

HYDRONIC FULLY SPECIFIED

CORRECT SIZING = SCHEMATIC MATCHING PUMP EQUIPMENT
EFFICIENCY YOUR PROJECT SCHEDULE READY

Introduction Table of contents

Distributed pumping can help improve the efficiency of
chilled water systems. This paper explores how to correctly
size pumps in a distributed network, addresses common
questions related to distributed pumping and provides
insight on benefits, including lower pressure and
horsepower requirements. The focus is on chilled water,
but the theories contained are applicable to hydronic
heating as well.
Pump sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
What is distributed pumping? . . . . . . . . . . . . . . . . . . . . . . . 2
Why use distributed pumps? . . . . . . . . . . . . . . . . . . . . . . . . . 3
Primary pumps in distributed pumping systems . . . . . . 3
Secondary pumps in distributed pumping systems. . . . 5
Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Prepared by Pavel Mirchev

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PUMP SIZING WHAT IS DISTRIBUTED PUMPING?

Chilled water hydronic applications have traditionally
been arranged two ways: primary with variable secondary
or variable primary pumps. Distributed pumping is an
introduction of a third style of hydronic pumping.
This paper will provide insight on how to properly size
pumps in a distributed network and address some of the
most common questions and selection pitfalls. The paper
will focus on chilled water, but the same theories apply to
hydronic heating.
In order to understand the subject matter of this paper it is
necessary to understand pump and hydraulic performance,
friction loss in piping networks and across chilling
equipment, and the general curves and data associated
with hydronic equipment. For the purposes of this
conversation, it is assumed that the standard systems
utilise control valves and circuit setters, and that piping is
set up in a two-pipe configuration.
Distributed pumping is a hybrid pumping arrangement
that combines variable primary and variable secondary
systems. Distributed simply means that the secondary
pumps are distributed through the piping network so as
to be located next to each zone (coil pumps) – specifically
the air handling unit (AHU) or bank of fan-coil units. These
distributed pumps are installed in place of control valves
and balancing valves. Primary pumps can provide for the
full system flow and circulation through the bypass line if
necessary. Figure 1A shows a traditional variable primary
design and Figure 1B illustrates the same application but
with distributed pumps.

DN125 DN125 DN125 DN100 DN100 DN80

Flow 23.88 L/s Flow 23.88 L/s Flow 19.1 L/s Flow 14.3L/s Flow 9.55 L/s Flow 4.78 L/s
30 m 25 m 10 m 10 m 10 m 10 m

1 2 3 4 5 6
CHILLER
CHILLER

PD 60 KPA
PD 24.5 kPa

Variable
primary design
M

CV PD 20 KPA
Figure 1A. Traditional variable primary arrangement
 3

DN125 DN125 DN125 DN100 DN100 DN80

Flow 23.88 L/s Flow 23.88 L/s Flow 19.1 L/s Flow 14.3L/s Flow 9.55 L/s Flow 4.78 L/s
30 m 25 m 10 m 10 m 10 m 10 m

1 2 3 4 5 6
CHILLER
CHILLER

PD 60 kPa

Grundfos distributed
Pumping design PD 24.5 kPa

Figure 1B. Distributed pump arrangement

WHY USE DISTRIBUTED PUMPS? PRIMARY PUMPS IN DISTRIBUTED PUMPING SYSTEMS

In conventional systems, pumps are used to create the
maximum pressure needed for the system’s most distant
consumer. Balancing and control valves are then used to
restrict the flow that is delivered to the rest of the
consumers that do not require the maximum head. If this
is not done, it will result in overflow. The pump duty point
will move to the right and the consumer that needs the
maximum head will not receive it. Distributed pumping
eliminates the flow-restricting balancing and control
valves and replaces them with pumps that produce only
the locally required flow and head. This reduces the
pressure requirements for the entire system, thereby
reducing the pumping energy required to move the rated
flow throughout the chilled water network. The reduction
in pump energy also results in significant energy savings.
The chilled water systems will also operate closer to the
designed delta temperature of the system, increasing
chiller performance efficiency.
In traditional chilled water systems, pumps can be sized in
two ways. Either the primary pumps are sized for the full
system flow and maximum pressure loss in variable
primary systems or they are sized for the full system flow
and pressure loss out to the bypass in a primary/secondary
arrangement. Here the secondary pumps are sized for
full flow and the maximum pressure drop through the
secondary loop. In distributed pumping, the primary
pumps are only sized for pressure loss through the bypass
in the mechanical room and along with full system flow.
See Figure 2 for flow path of the primary pump.
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DN125 DN125
Flow 23.88 L/s Flow 23.88 L/s
30 m 25 m

1 2
CHILLER
CHILLER

PD 60 kPa

Grundfos distributed
Pumping design PD 24.5 kPa

Figure 2. Flow path of the primary pumps

What happens if the full system pressure is removed What about minimum flows through the chillers?
from the primary pumps? The first responsibility for the primary pumps in a
If the pressure loss for the full system is not required when distributed pumping arrangements is to ensure there is
selecting the primary pumps, pump size can be drastically minimum flow back to the chiller. The system utilises an
reduced compared to a variable primary arrangement. open, free-flowing de-coupler, so the primary pumps
In the case of primary variable secondary pumping simply bypass flow to maintain minimum flows. If the
arrangements, the primary pumps are sized for full system minimum flows are satisfied, the primary pumps will then
flow at constant speed. However, they only pump against work to balance themselves with the secondary pumps.
the pressure to reach the bypass line at the variable
secondary. The sizing of the primary pumps in distributed
pumping is done similarly with the exception of variable
speed. These pumps can operate at constant speed like
traditional primary pumps in a primary/secondary
arrangement, but to maximize energy savings and delta
temperature improvements, these pumps should be
variable speed.

SECONDARY PUMPS IN DISTRIBUTED PUMPING SYSTEMS
For systems utilising variable primary pumps, no secondary
pumps are required. In primary/secondary arrangements,
the secondary pumps are sized for full system flow and
maximum pressure loss throughout the entire secondary
network. Balance valves are then used to set the flow
requirements for each zone or AHU. Since valves are flow
inhibitors, the pressure requirements for the secondary
pumping system increases each time this process takes
place in a network. This also increases pump horsepower
requirements.
CHILLER
Figure 3. Locations of the distributed pumps
5
What happens when the secondary pumps are
distributed?
When the pumps are distributed into the piping networks
in place of valves, a flow inhibitor is replaced by a flow
initiator, which makes the system as “free-flowing” as
possible. This process greatly reduces friction losses in the
piping network, which means less horsepower is required
to pump the secondary side of the system.
Are the distributed pumps sized the same way as
traditional secondary pumps?
The secondary pumps in a distributed pump network are
located at each zone, specific to an AHU or a bank of fan-
coil units. If the system has multiple zones, it will require
multiple distributed pumps. See Figure 3 for the location
of the distributed pumps.

Since each zone requires its own pump, each pump should
be sized for the flow in its zone, taking into account friction
loss through that AHU and the piping loop tracing back to
the de-coupler. See Figure 4.
What are the key points to consider when determining the
flow and head for the pump?
The flow for the distributed pump is determined by the
flow required for the specific zone it is supplying. The head
calculation should include loss through the AHU, check
valve, and the friction loss of the supply and return piping
loop from the de-coupler to the pump. The piping’s friction
loss should be determined for the worst-case scenario –
maximum system flow. This means that friction loss in the
common supply and return line should be determined by
using the total flow of all the distributed pumps if there is
more than one zone connected to the system.
DN125 DN125
Flow 23.88 L/s Flow 23.88 L/s
30 m 25 m
1 2
CHILLER
CHILLER
PD 60 kPa
Grundfos distributed
Pumping design
PD 24.5 kPa
Figure 4. Piping loop for distributed pump.
6
Will the pumps cross-flow into other zones?
Distributing the pumps in a chilled water network requires
removing the control valves and the balancing valves and
replacing them with a pump. Without a control valve in
place, the pump will be exposed to back-flow when it is not
operating. Because of this, a low resistance check valve is
required for discharge on the sides of each distributed
pump. This check valve will prevent back-flow in the
system. See Figure 4 for the location of each check valve.
How is the distributed pumping system balanced if there
are no balancing valves?
The pumps auto-balance the system. All that is required
during commissioning is to set maximum pump flow for
each of the distributed pumps based on the maximum
flow for the AHU/zone being serviced. Doing this ensures
the system never runs out of balance and will not need
rebalancing after years of operation. The pumps will
continuously readjust to changes as equipment ages,
ensuring optimal operation throughout the entire lifetime
of the equipment.
DN125
Flow 19.1 L/s
10 m
3
 7

What additional input is needed to size a distributed CONCLUSION

pumping system?
Because distributed pumping delves further into overall
system design, more information is needed than for
traditional pump selections. For these applications,
Grundfos requires schematic layouts and equipment
schedules. The information needed in a schematic includes
pipe details (diameter and length), fitting details, and
number of risers. This information can be estimated but
the more exact it is at the design stage, the more efficient
the system will operate. The flow and pressure drop for the
scheduled equipment (chillers, AHU, fan-coil units, etc.) is
also needed.
Distributed pumping is an excellent way to improve the
efficiency of your chilled water system. By removing the
valves from the system and installing pumps in their place,
a “free-flowing” system is created, reducing the overall
system pressure. This pressure reduction also means less
system horsepower is needed to operate the system,
simultaneously addressing low delta temperature
syndrome.

Key information:
1. Building schematic
2. P ipe schematic including pipe diameter and length.
As .dwg or pdf file.
3. Equipment schedule of: Chillers, Airhandling units,
Fan coil units, Conventional pumps
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