RETROFIT IN HVAC
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Retrofi tting pumps? Think installation as well as energy effi ciency
Retrofi tting new HVAC pumps is a tried and tested way of reducing a site’s energy consumption, but all too often the cost-savings stop there. In many cases, valuable opportunities to reduce the overall cost of the retrofi t will be left on the table. Chances of cutting embodied carbon, or of reducing installation time and complexity, are overlooked all too frequently. So what are these overlooked opportunities, asks Peter Wolff , global manager, ecosystems & performance upgrades at Armstrong Fluid Technology
Think embodied carbon The fi rst thing to consider when planning the retrofi t, is whether the pump bodies can be retained. Some commercial-scale pumps (including many Armstrong models) enable the pump head/rotating assembly to be updated whilst leaving the pump body in place. This reduces cost and disruption for the upgrade of the pump and can unlock signifi cant savings. It can also make a considerable impact on the sustainability aspects of the project. There are other ways of reducing the embodied
carbon of the retrofi t too. Before replacing ‘like-for- like’, ask yourself whether the same amount of pump hardware is going to be necessary going forward. For example, full duty/standby pump installations are extremely common. One pump (sized for full duty) is operational while another of the same size is out of action, simply there to accommodate 100% redundancy in the event of routine maintenance or pump failure. There are energy effi ciency implications of this, as the single pump will typically be operating at well below its design duty for most of its operating life on typical variable fl ow systems, delivering poor effi ciency and shorter life. There are also cost and embodied carbon impacts of the full duty/standby approach. Whilst full duty/standby may be necessary for
peace of mind in high reliability installations, such as hospitals and data centres, there are far more sustainable, effi cient and cost-eff ective ways of
24 June 2026
Left: Peter Wolff , global manager, ecosystems & performance upgrades at Armstrong Fluid Technology
Minimise piping and pump accessory requirements
safeguarding pump operation in medium and low risk applications. An alternative is to specify two smaller pump heads in a common casing, each sized for 50% of the design fl ow. This reduces fi rst installed and lifecycle costs, frees up space in the plant room or energy centre, and potentially halves the embodied carbon for the installation. The smaller heads will be at better effi ciency, working their sweet spot at lower loads than a single larger head pump. The service and maintenance advantages are
obvious. In the case of the Armstrong Design Envelope Tango range, for example, integrated valves can isolate one side of the pump for servicing, whilst the other pump remains in operation. This maintains fl ow and ensures occupant comfort whilst routine maintenance is carried out. As the actual capacity of each pump is, in practice, greater than 50% (for example 70% of capacity in the case of a Tango module with 2 x 4kW pumps) this option can handle peaks or lows in outside temperature without problems.
Many of the typical list of materials for the installation aspects of the retrofi t project could actually be unnecessary. Installing pumps within the pipework, for example, eradicates the need for inertia bases. Sensorless pumps (with controls incorporated into the pumps themselves to adjust automatically to demand) also do away with the need for components such as pressure sensors or wall-mounted VFDs, which increase the time and cost elements of installation. Multi-function pump accessories can also speed up the retrofi t project. An example is the Armstrong Suction Guide which eradicates the need for a separate conventional Y Strainer, a long radius elbow, a pipe-size reducer and an inlet spool piece, as well as all of their associated fl anges, nuts, bolts and gaskets.
Futureproofi ng
Advances in real-time cloud monitoring have revolutionised preventative maintenance and can ensure that pump performance does not drift over time. In the case of Armstrong pumps, these capabilities are available as standard. Split-coupled pumps featuring external seals, can enable all mechanical seal components to be withdrawn for servicing without the need to disturb other pump components or the motor. For larger pump sizes this can also reduce the cost and health and safety implications of using specialist lifting equipment when carrying out seal changes. To conclude, by looking beyond energy effi ciency
alone, you can deliver an even smarter and more cost-effi cient pump retrofi t project.
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