SUSTAINABILITY


4 top tips to avoid pump peformance shortfall


Pump technologies such as advanced control, machine learning and embedded intelligence are delivering valuable fi nancial and environmental advantages. However it is still important to ensure that ineffi ciencies are not inadvertently built into pumping systems from the outset, and that performance does not diminish over time. Peter Wolff , global manager, ecosystems and performance upgrades at Armstrong Fluid Technology off ers top four tips


1. Don’t oversize from the outset Be very wary of ‘like-for-like’ replacement of pumps without reviewing the specifi c requirements of the application. For example, the traditional method of assessing system fl ow rate, with built-in safety factors, results in an oversized pump that’s regularly running at way under the design fl ow number, reducing its operating effi ciency and its lifetime. A better solution is to split the system fl ow rate between two or more pumps. Today’s intelligent pump models, such as the Armstrong Design Envelope range, can talk to each other and stage themselves in and out, delivering higher effi ciency across a much broader operating range. Depending on the project, you might also feel


forced into oversizing pumps in systems that need to expand incrementally over time, such as data centres and district energy networks, risking technical problems as well as ineffi ciency. Today’s modular packaged HVAC solutions


are designed for eff ective scaling-up, so look for solutions that are already designed with incremental expansion in mind. This avoids costly customisation and provides much predictability and repeatability of environmental performance. Scalable energy centres and/or temporary energy centres can also provide fl exibility for large complex projects like these, as can pumps with a wider operational range.


2. Ensure pumps operate along their natural curve


Today’s variable speed systems typically operate at between 10% and 60% of design fl ow nearly all of the time. So demand-based control improves effi ciency by meeting the actual load in the most


20 March 2026


Left: Peter Wolff , global manager, ecosystems and performance upgrades at Armstrong Fluid Technology


www.heatingandventilating.net


eff ective way. Pumps incorporating Sensorless control have signifi cant advantages in delivering demand-based control, as they automatically adjust to changing demand whilst reducing system complexity.


So when designing a system, look for pump models with embedded intelligence which enable the rotating device to operate along its peak effi ciency natural curve, as this can increase operating effi ciency by up to 400%. These options maintain the pump affi nity law relationship between pressure and rotary speed, along the natural curve at decreased speeds, adjusting automatically to changes in load. Equipment loading can be optimised across the system as a whole, to achieve signifi cant reductions in energy consumption.


3. Optimise pump staging


Traditional pump staging strategies turn on the next pump when the existing or current pumps reach 95% of maximum speed. Pumps are typically staged off when the existing or current pumps slow down to 55% of maximum speed. Both of these scenarios (staging pumps on too late, and off too early) involve lost effi ciency. The best practice alternative is to adopt effi ciency-based staging points (as opposed to


staging points based on pump speed). This enables the system to “surf” across the top of the effi ciency curves throughout the day, eliminating wastage inherent in pump speed-based control approaches, achieving energy savings of over 30%.


4. Prevent operational drift


Operational drift can occur over time, often as a result of adaptations to the system after installation. These issues can now be overcome easily using cloud computing and machine learning. The advanced connectivity of today’s pump models provide the custodian with real time monitoring on browsers or apps, reducing energy costs, improving environmental performance, and predicting potential technical issues, at any stage in the lifecycle of a building. Armstrong’s Envelope Advisor, for example, analyses the whole HVAC system’s operation eff ectiveness, air and water side, comparing it with industry standard guidelines, highlighting issues that need fi xing and what they’re costing so that the operator can apply an early fi x. You don’t have to replace the complete pump to harness this functionality. Many pump 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.


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