Professional Documents
Culture Documents
by:
ASHRAE India Chapter and Xylem, Inc.
Presented by:
Larry Konopacz, Manager of Training & Education
Bell & Gossett Little Red Schoolhouse
Saturday, September 21, 2013
Whats a Ton?
I Ton Ice =
2000 LB;
1LB Ice =
144 Btu;
1 Ton ice =
288,000 Btu
Rule of 24
12,000 Btu/h = 500 x gpm x tF = 1 ton
gpm/ton = 12,000/(500 x tF)
= 24/tF
Centrifugal
Rotary screw
Reciprocating
Absorption
Condenser
Evaporator
Refrigeration Cycle
Expansion Device
Hot Water
Liquid Flow
Vapor Flow
Condenser
Water Pump
Compressor
Motor
Load
Evaporator
Cool Water
Condenser
Cooling
Tower
Supply
Water
Return
Water
Chilled
Water
Pump
Chiller 2
Chiller 1
Return
Common Pipe
Supply
Chiller 1
Supply
Triple
Duty
Common
Pipe
Return
Triple
Duty
Chiller 1
Supply
Triple
Duty
Common
Pipe
Return
Supply
Triple
Duty
Chiller 1
Common
Pipe
Triple
Duty
Return
SRS
Towers
SRS
SRS
Pumps
Triple Duty
Condenser
Condenser
Condenser
SRS
Standby Pump
Tower Equalization
Cooling Towers
Equalization
Line
Condenser
Condenser
SRS
Triple Duty
Condenser
SRS
SRS
Cooling Towers
Air in
Air out
Water In
Water out
Water in
Air in
Water out
Air in
Air in
Air in
Water out
Water in
Range
(R F)
Approach
(F)
Wet bulb F
Heat Load = L x R
L lb/min of water
Load
L lb/min of water
Hot water F
Cold water F
Water Flow
Types of Free-Cooling
(Waterside Economizer)
Air Out
Water in
Air in
Air in
Water out
Earth Contact
Evaporative
Heat Exchangers
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TOWER
E
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A
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GPX
H
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A
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C
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LOAD
Triple Duty
Sediment Removal
Separator
Triple Duty
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TOWER
E
V
A
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GPX
H
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LOAD
Triple Duty
Sediment Removal
Separator
Triple Duty
Evaporative Characteristics
Heat rejection device (tower) exists.
As temperature declines, opportunity
arises.
Higher sensible vs. latent loads
Leaving water temperature approaches
42 F.
Freeze protection may be required.
Freeze Protection
Sump heaters.
Close temperature control.
Accurate water level control.
Prevention of moist air recirculation.
External piping freeze protection.
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TOWER
E
V
A
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LOAD
Triple Duty
Sediment Removal
Separator
Triple Duty
NOT RECOMMENDED
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TOWER
E
V
A
P
Triple Duty
Sediment Removal
Separator
LOAD
Triple Duty
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TOWER
E
V
A
P
GPX
H
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A
T
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C
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LOAD
Triple Duty
Sediment Removal
Separator
Triple Duty
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TOWER
E
V
A
P
GPX
H
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A
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C
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LOAD
Triple Duty
Sediment Removal
Separator
Triple Duty
57= T1
CH. WATER
52= t2
7F TEMPERATURE
CROSS
45= T2
COND. WATER
3F COOLING
APPROACH
42= t1
EXCHANGER
LENGTH
CH. WATER
EWT LWT FLOW
LMTD
DEG F
AREA EXCH.
SQ.FT. MODEL
COST
INDEX
42
52
1000
57
45
834
3.92
1390
GPX807
1.00
42
52
1000
58
46
834
4.93
1135
GPX807
0.85
42
52
1000
59
47
834
5.94
975
GPX807
0.76
Temperatures are in F
Flow is in USGPM
Approach = 3F
10/4.93=2.03
Approach = 4F
10/5.94=1.69
Approach = 5F
Application Criteria
Economics
Storage Media
Storage Technologies
System Configurations
Application Criteria
Storage Media
Chilled Water
Ice Harvesting
External/Internal Ice Melt
Warm
Vent
Storage
Pressure sustaining
and check valve
Cool
Constant volume
primary pump
Chiller
Temperature Stratification
Top 0
Depth of tank, ft
-5
-10
Thermocline
-15
Bottom -20
30
40
50
60
Temperature, F
70
Primary
pump
Chiller
Transfer
Pump
Direction
control
valves
Vent
Warm
Pressure sustaining
and check valve
Storage
Cool
Constant volume
primary pump
Heat
Exchanger
Variable volume
primary
pump
Warm
Vent
Storage
Cool
Constant volume
primary pump
Pressure sustaining
and check valve
Chiller
Load
Ice water
Chilled water
pump
recirculation
pump
Discharging Mode
Charging Mode
Discharging Mode
Ice
Cold glycol
Ice
Warm glycol
Water
Charging
Storage
Charging
Storage
Chiller off
Tons
Cooling load
(met by storage)
Chiller meets load directly
Time of Day
Cooling load
(met by storage)
Tons
Time of Day
Charging
Storage
(met by storage)
Tons
Cooling load
(met by chiller)
Time of Day
Charging
Storage
System Water
Return
Air Coil
Water Coil
Air Coil
Water Coil
(Evaporator)
(Condenser)
(Condenser)
(Evaporator)
Cool
Air
Warm
Air
Compressor
Reversing
Valve
Capillary
Refrigerant
Loop
Compressor
Reversing
Valve
Capillary
Design Considerations
Use slow closing two-way valves for
each zone
Good system balance required
Use staged c/s or v/s pumps
Use with cooling towers and GPX
Use with closed circuit cooling towers
Water Source
Heat Pump
Buffer
Tank
( Optional )
Gasketed
Plate Heat
Exchanger
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Buffer
Tank
( Optional )
Compression
Tank
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Comments?
Questions?
Observations?
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A Problem
We want:
a. variable volume, to save pumping
costs at part load,
b. constant flow through the chiller to
protect it.
A Solution
a. constant flow primary system for the chillers
b. variable flow secondary system for the load
Primary-Secondary Terms
Supply
Primary Loop
Production
Secondary Loop
Distribution
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Primary-Secondary
Common Pipe
Return
Fundamental Idea
Secondary
Pump
Primary
Pump
Tee
A
Tee
B
Primary-Secondary Pumping
The idea is based on:
Conservation of Mass
Conservation of Energy
100 GPM
50 GPM
60 GPM
40 GPM
No Secondary Flow
Secondary
Pump
Off
A
100 GPM @ 45F
Primary
Pump
Primary = Secondary
Pump On
A
100 GPM @ 45F
B
0 GPM
50 GPM @ 45F
50 GPM @ 55F
Pump On
Mixing at Tee B
Pump
On
Two-way Valve
Primary-Secondary Pumping
Supply
Primary Loop
Production
Secondary Loop
Distribution
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Primary-Secondary
Common
Return
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
Common
Return
10 dia.
Control Valves
Opening
H3
Head
Flow
F1
F2
F3
Typical System
Distribution
Production
45F
To Loads
Chiller 1, on
Chiller 2, off
Secondary Pumps
1500 gpm each
Common
1500 gpm
each
From Loads
Production = Distribution
CHWS Temp
45oF
1500
1500
Chiller 2, off
Chiller 1, on
Secondary
Pumps
1500
Common -- No Flow
0
1500
1500
ECW Temp
55oF
CHWR Temp
55oF
2000
1500
Chiller 2, off
Chiller 1, on
Secondary
Pumps
2000
Mixing (1500 @ 45) + (500 @ 55)
Common -- 500
1500
2000
ECW Temp
55oF
CHWR Temp
55oF
Chiller 1, on
Chiller 2, off
0 GPM
Be Careful!
Common
Return
>1500 GPM
>1500 GPM
@ 55oF
Linear
Function
Step
Function
Chiller 1
Chiller 2
Chiller 3
Primary/Secondary
Common
Distribution
Production
Return
20
15
10
5
0
0-10
30-40
60-70
% Load
90-100
Multiple Chillers
Chiller 1
Chiller 2
80
% Load
60
40
20
1
25
50
2
75
% Time
100
Chiller 1, 40%
Chiller 2, 60%
100
CHWS Temp
45oF
3000
Chiller1, on
Chiller 2, on
Secondary
Pumps
2100
Common -- 900
1500
2100
ECW Temp
52oF
CHWR Temp
55oF
Loading a Chiller
A chiller is a heat transfer device. Like
most equipment, it is most efficient at
full load.
To load a chiller means:
Supply it with its rated flow of water
Insure that water is warm enough to permit
removal of rated Btu without freezing the
water
KW per Ton
0.9
0.8
0.7
0.6
0.5
10 20
30
40 50 60 70
Percent Load
80 90 100
20
15
10
5
0
0-10
30-40
60-70
% Load
90-100
80
% Load
60
40
20
1
25
50
2
75
% Time
100
Chiller 1, 40%
Chiller 2, 60%
100
Chiller 3
and
Chiller 2
80
60
% Load
40
Chiller 3
20
Chiller 1
or
Chiller 2
25
50
75
100
% Time
Chiller 1, 40%
Chiller 1
Chiller 2, 40%
Chiller 3, 60%
100
% Load
Time
75
% Flow
Ch 1
Ch 2
50
Ch 1
Ch 2
Ch 3
Ch 3
Ch 4
25
Ch 2
Ch 1
25
50
75
% Load
100
Chiller 1
Chiller 2
Chiller 3
Common
From loads
Production = Distribution
CHWS Temp
45oF
1500
1500
Chiller 1, on
Chiller 2, off
Common
0 Flow
Secondary
Pumps
1500
1500
1500
CHWR Temp
55oF
500
Chiller 1, on
Chiller 2, off
Common
500 gpm
Secondary
Pumps
1500
2000
1500
2000
500
CHWR Temp
55oF
1500
Chiller 1, on
Chiller 2, on
Common
900
600
1500 GPM
@ 49oF
900 GPM
@ 45oF
Secondary
Pumps
1500
2100
1500 GPM
@ 55oF
600 GPM
@ 55oF
2100
CHWR Temp
55oF
Supply
Free Cooling
Chiller 2
Chiller 3
Pump
Controller
Return
Primary-Secondary System
Secondary
Pumps
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
PrimarySecondary
Common
Return
BHP
100
75
Secondary Pumps +
50
25
50
75
100
C/S Pump
(2 Way Valve)
130
120
Base
Design
HP %
110
100
90
80
70
60
% Full Load 50
(Design) HP 40
30
20
10
0
10 20 30 40 50 60 70 80 90 100
% Flow
300
250
c/s @ 1.0
Yearly Operating Cost x $1000
c/s @ 1.25
200
c/s @ 1.50
c/s @ 2.0
150
100
50
0
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
Lead times
Additional Concerns
Pump Protection at minimum flow
Chiller Staging and De-staging
instrumentation.
Pump Protection
Bypass Options
1. Establish a minimum flow equal to or greater than
the minimum required to protect the pump.
2. Install a bypass at the end of the mains with a
balance valve to set minimum flow.
3. Install a bypass at ends of zones.
4. In retrofits, leave a three way valve at the end of the
system.
5. Use P or flow sensing to open pump bypass only
when needed.
6. V/S pumps are not as big a problem because of
lower head at reduced flow.
Secondary
Constant Speed
Pumps
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
6
Primary
Secondary
Common
Return
TS-S
TP-S
FS
FP
To Loads
Chiller 1, on
Chiller 2, off
Secondary/Pumps
Distribution
Common
TP-R
TS-R
From Loads
Flow Switches
Chiller 1
Chiller 2
Secondary/Pumps
Common
From Loads
Comments?
Questions?
Observations?
20%
15%
5%
2%
3%
15%
5%
3%
2%
Inverter section
forms a synthetic sine wave
several varieties available
maintains a controlled frequency/voltage ratio
Affinity Laws
1. Capacity varies as the RPM change ratio:
FLOW 2 = FLOW 1 ( SPEED2 / SPEED 1)
2. Head varies as the square of the RPM change ratio:
HEAD 2 = HEAD 1 (SPEED 2 / SPEED 1)
Percent
90
80
Flow
70
Head
60
Horsepower
50
40
30
20
10
0
0
10
20
30
40
50
60
70
Flow/Speed, Percent
80
90
100
Theoretical Savings
120
110
Pump Curves
100
90%
100% Speed
110
100
Design
90
90
80%
80
Head
70
70
70%
60
50
60
50
60%
40
HP Draw
50%
30
40%
30
Head
20
BHP
10 30%
0
0 10 20
40
Flow
30 40
50
60
70 80
% Design Flow
10
0
90 100
% BHP
% Head
80
20
120
P Sensor/Transmitter
25 Ft. Head
System Curve
& V/S Control System
110
25 FT Differential Head
Maintained Across Load
(Set Point)
80
60
Overall
system curve
40
Distribution
piping head
loss curve
20
0
200
400
600
800
Flow
Set Point
Pump TDH
Head
100
1600
100
80
Pump TDH
Head
Set point,
25 FT
Control curve
60
Overall system curve
40
Distribution
piping head
loss curve
20
0
0
200
400
600
800
1000
1200
1400
1600
Flow
*Whats Constant?
Pump
Initial Speed
Control Curve
B
Head, H
(feet)
Pipe, Fitting
Friction Loss
Flow, Q
(gpm)
Q2 Q1
Pump
Curve
Speed 1
B
Speed 2
Control Curve
A
Head, H
(feet)
Pipe, Fitting
Friction Loss
Flow, Q
(gpm)
Q3 Q2
Q1
Control Curve
Speed 1
Head
(ft)
Final Speed
Pipe, Fitting
Friction Loss
Flow, Q
(gpm)
Q4
Q1
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Pump
Controller
Return
Base 100
90
80
70
V/S, 25% Variable Hd Loss, 75% Constant Hd
60
50
40
30
V/S, 100% Variable Hd Loss, 0% Constant Hd
20
10
0
10
20 30 40
50 60 70 80 90
% Flow
100
150
140
C/S Pump
(2 Way Valve)
130
120
Base
Design
HP %
110
Constant Flow, C/S Pump
100
(3 Way Valve)
90
Pump HD Matched
to System @
Design Flow
80
70
60
% Full Load
(Design) HP
50
* 25/75 Means:
25 % Variable HD Loss
75 % Constant HD Loss
40
30
20
10
0
10
20
30 40
50 60
70 80 90
100
V/S Curves
120
50 %
110
60 % 70 %
80 % 85 % % Efficiency
85 %
80 %
100
100 %
90
Head, Feet
80
90 %
70
% Speed Curves
80 %
60
50
70 %
40
Constant
Efficiency
Curve
60 %
30
50%
20
40 %
30 %
10
0
100 200
300 400
500
GPM
600
700 800
900 1000
Efficiency Changes
50 %
120
60 %
110
70 % 80 %
% Efficiency
85 %
85 %
80 %
100
100 %
90
Head, Feet
80
90 %
70
% Speed Curves
80 %
60
50
70 %
40
Constant
Efficiency
Curve
60 %
30
50%
20
40 %
10
0
30 %
0
100 200
300 400
GPM
500
600
700
800
900 1000
120
60 %
110
% Efficiency
70 % 80 %
85 %
85 %
80 %
100
100 %
90
Head, Feet
80
90 %
70
% Speed Curves
80 %
60
50
70 %
40
Constant
Efficiency
Curve
60 %
30
50%
20
40 %
10
0
30 %
0
100 200
300 400
GPM
500
600
700
800
900 1000
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Pump
Controller
Return
Pump 1
Pumps 1 & 2
Control Curve
1770 RPM
1450 RPM
1150 RPM
600 RPM
900 RPM
Pumps 1, 2 & 3
Set Point
(Input Signal)
Technologic
Pump
Controller
Feedback
Signal
Sensor/
Transmitter
Set Point
+/- error
Adjustable
Frequency
Drive
(Controlled Device)
Controlled
Variable
System
Pressure
Differential
Pressure
4-20
ma
signal
Temperature
Differential
Temperature
Flow
Pump
Controller
3f , 60 Hz Power
(Control Agent)
Set Point
(Input Signal)
Technologic
Pump
Controller
Feedback
Signal
Sensor/
Transmitter
Set Point
+/- error
Adjustable
Frequency
Drive
(Controlled Device)
Controlled
Variable
System
Technologic Pump
Controller
Controls pumps and drives
Accept set point, analyze sensor input
PID function
Pump staging
Pump alternation
Recognize and react to component failure
Provide message display
Central management system link
Safeguard system
PID Control
3f , 60 Hz Power
(Control Agent)
Set Point
(Input Signal)
Technologic
Pump
Controller
Feedback
Signal
Sensor/
Transmitter
Set Point
+/- error
Adjustable
Frequency
Drive
(Controlled Device)
Controlled
Variable
System
Rectifier
Section
Direct
Current
Inverter
Section
Variable
Voltage &
Frequency
Power
Pump
Motor
Efficiency, %
100
60
Currently Available
AFDs
Typical Older AFDs
40
Other Types
80
20
0
0
20
40
60
Design Speed, %
80
100
The Pump
Minimum Flow
Minimum Speed
Inverter Duty
Motors
Motor Couplers
110
100
90
Head
80
70
60
30% Speed
50
40
30
20
10
0
10
20
30
40
50
% Flow
60
70
80
90
100
Variable Flow
Through
The Evaporator
Primary-Secondary System
Constant Differential Head Loss
Variable Head Loss
Supply
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Pump
Controller
Return
Primary-Secondary
Common Practice.
Why?
Protection.
Nuisance shutdowns.
Freezing.
Costly downtime.
DP Sensor
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DP Sensor
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DP Sensor
DP Sensor
Modulating
Valve
AFD
AFD
AFD
Controller
Whats different?
Primary pumps only
Flow meters or p sensors at each
chiller.
Two-position isolation valves at each
chiller
Minimum flow bypass with a modulating
control valve.
Smarter controller.
Alternative #1
Ganged Pumps
FLOW
METER
SUPPLY
F
SIGNAL
TO TECH
DP
SENSOR
DP
SENSOR
DP
SENSOR
CHILLER
DP
SENSOR
CHILLER
DP
SENSOR
CHILLER
SIGNAL
TO TECH
SIGNALS
TO TECH
SIGNAL
TO TECH
SIGNALS
TO TECH
SIGNALS
TO TECH
TDV
TDV
TDV
T
NOTE:
ALL SENSOR
SIGNALS WIRED TO
TECHNOLOGIC
5500
RETURN
AFD
AFD
AFD
ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
BYPASS:
FOR SYSTEMS WITH
EXTENDED LIGHT
LOADS/WEEKEND
SHUTDOWNS. SET
BALANCE VALVE
FOR LOW FLOW TO
REDUCE THERMAL
STRATIFICATION
AND ALLOW QUICK
START UP AFTER
SHUT DOWN.
Technologic 5500
Initial programming is
crucial.
Must use accurate data
from the chiller
manufacturer.
Start-up coordination
should include the BMS
too.
Alternative #2
Bypass at End of System
Minimum chiller flow
Minimum pump flow
Ganged Pumps
FLOW
METER
SUPPLY
F
SIGNAL
TO TECH
DP
SENSOR
DP
SENSOR
CHILLER
DP
SENSOR
CHILLER
SIGNALS
TO TECH
CHILLER
DP
SENSOR
SIGNAL
TO TECH
SIGNALS
TO TECH
DP
SENSOR
SIGNAL
TO TECH
SIGNALS
TO TECH
TDV
TDV
TDV
T
NOTE:
ALL SENSOR
SIGNALS WIRED TO
TECHNOLOGIC
5500
RETURN
AFD
AFD
AFD
ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
Alternative #2
Minimum flow bypass valve is controlled
to protect both the pumps and the
chillers.
Pump requires >25% BEP flow
Minimum flow of largest chiller
Alternative #3
FLOW
METER
SUPPLY
F
SIGNAL
TO TECH
DP
SENSOR
DP
SENSOR
CHILLER
DP
SENSOR
DP
SENSOR
CHILLER
DP
SENSOR
CHILLER
SIGNAL
TO TECH
SIGNALS
TO TECH
SIGNALS
TO TECH
TDV
SIGNAL
TO TECH
SIGNALS
TO TECH
TDV
TDV
T
NOTE:
ALL SENSOR
SIGNALS WIRED TO
TECHNOLOGIC
5500
RETURN
AFD
AFD
AFD
ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
BYPASS:
FOR SYSTEMS WITH
EXTENDED LIGHT
LOADS/WEEKEND
SHUTDOWNS. SET
BALANCE VALVE
FOR LOW FLOW TO
REDUCE THERMAL
STRATIFICATION
AND ALLOW QUICK
START UP AFTER
SHUT DOWN.
Pump Selection
Equal size pumps.
Redundancy.
Parts.
Maintenance.
Chiller Selection
Equal size chillers.
Redundancy.
Parts.
Maintenance.
Design Considerations
Size bypass for minimum flow of largest chiller.
Minimum building load?
Design Considerations
Sequence chillers based on p or temperature
sensors.
Use accurate, calibrated flow meter or p sensors
at each evaporator
Allow for operator training.
Initial
On-going
Turn-down Ratio
Chiller manufacturers publish 3 - 11 fps
evaporator velocity range (typically).
You may have to increase your
acceptable head loss targets, use more
pump head.
Nominal base of 7 fps desirable.
Variation of 1 to 2 fps.
Work with the manufacturer.
Rate of Change*
Maximum rate of flow change, % design flow per minute
Source
Vapor Compression
Absorption
#1
4-12
**
#2
20-30
2-5
#3
**
30
#4
**
#5
**
1.67
*Table 2-2
ARTI-21CR/611-20070-01, 2004, Bahnfleth & Peyer
** Information not provided
Application specific.
Consider thermal storage
Operator Ability
Within operators ability?.
Commercial buildings may not have well
qualified operators.
Training is mandatory.
Initial
Periodic, in view of operator turnover.
Controls Complexity
Additional controls for the chillers
Additional controls the pumps.
Pumps operate on flow, temperature, and
P.
Chiller P.
Sensor Calibration
Multiple sensors control:
Flow.
Temperature.
Delta p
Maintenance.
Calibration.
Summary
Evaluate all the options.
Read some articles:
Variable Primary Flow CHW: Potential Benefits and Application Issues
by Bahnfleth and Peyer. Pennsylvania State University, ARTI21CR/611-20070-01
Chilled Water System for University Campus by Stephen W. Duda, PE,
ASHRAE Journal May, 2006
Comments?
Questions?
Observations?
Primary-Secondary-Tertiary
Zone C
Zone A
Zone B
C
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C
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Zone B
WRONG !
C
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C
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L
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DP Controller
Zone C
Zone B
WRONG !
C
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L
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C
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Zone C
Automatic
Flow Control
Valve
Primary-Secondary-Tertiary
Zone C
Zone A
RIGHT !
C
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Zone B
C
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Primary-Secondary-Tertiary
can be even more useful
Zone C
Zone A
Zone B
C
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?
Optional Variable
Speed Pump
Load
Load
T1
Tertiary
Zone
Pump
MV
MV
MV
T4 T1
Common
T2
T2
T3
Pumped
Chilled
Water
Supply
Circuit Setter
Chilled
Water
Return
T3
T4
Tertiary Bridge
Load
Load
Load
MV
MV
MV
T1
Tertiary
Zone
Pump
T4
Common
T2
T3
Pumped
Chilled
Water
Supply
Tertiary Bridge
Chilled
Water
Return
Load
Load
T1
Tertiary
Zone
Pump
MV
MV
MV
T4 T1
Common
T2
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3
T4
ADVANTAGES
1. Permits operating at highest allowable zone temperature
2. Maximizes coil flow rate, good film coefficients
3. Maximizes flow rate through each control valve
4. Ensures good humidity control
5. Minimizes the amount of coil reheat
DISADVANTAGES
1. Temperature of return water is unknown
2. Temperature of return water to chiller may be too high
3. Will not recognize increased supply water temperature
T2 Operation
Load
T1
Tertiary
Zone
Pump
MV
Load
MV
Load
MV
T4 T1
Common
T2
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3 T4
ADVANTAGES
1. Maintains chilled water return temperature at setpoint
2. Will not overload the chiller
DISADVANTAGES
1. No control of zone supply water temperature
2. Could lose humidity control
3. Will not recognize increased supply water temperature
T3 Operation
Load
Load
Load
T1
Tertiary
Zone
Pump
MV
MV
MV
T4
Common
T1
T2
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3 T4
ADVANTAGES
1. There are no perceived advantages at this location
DISADVANTAGES
1. Little, if any, valve modulation unless it is set to
close on sensing supply temperature lower than
permissible in the zone
T4 Operation
Load
Load
Load
T1
Tertiary
Zone
Pump
MV
MV
MV
T4
T1
Common
T2
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3
T4
ADVANTAGES
1. Maximizes coil flow rate
2. Ensures good humidity control
DISADVANTAGES
1. Temperature of return water is unknown
2. Temperature of return water to chiller may be too high
3. Will not recognize increased supply water temperature
Load
Load
MV
MV
MV
T1
T2
T1
Tertiary
Zone
Pump
Common
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3
Control Algorithm
1. Temperature control to the zone (T1 sensing).
2. If T1 is satisfied, return water temperature to the chiller
plant (T2 sensing).
3. Monitor secondary chilled water supply temperature
(T3 sensing) for temperature increase due to secondary
return water recirculation or temperature decrease due to
chiller leaving water temperature reset.
4. Reference point for automatic reset and T (T2 - T3)
control (T3 sensing).
So what?
Satisfy zone cooling requirement at the
maximum possible supply temperature
Minimize secondary flow rate
Optimize return water temperature
Tertiary
Pump
Chiller Plant
Secondary Pumps
Tertiary
Pump
Tertiary
Pump
Problems
Bypass returns cold water to chillers,
reduces system t.
Linear valve characteristics can cause
increased flow at part load.
Balancing required in bypass pipe and
coil-to-coil.
High cost per ton at the chiller.
MV
Load
MV
Load
MV
T1
T1
Common
Flow
Meter
T3
Small
By-Pass
Secondary Supply
Secondary Return
T2
T2
T3
Multi-zone Application
Zone 1
Zone 2
Zone 3
Terminal
Unit Balance
Valve
Terminal
Unit Control
Valve
Zone 4
Zone
(Tertiary)
Pump
Zone Supply
Temperature
T1
T1
Chiller Supply
Temperature
T3
Common
GPX
Flow
Meter
C
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Common
T3
]e
C
Distribution
o
(Secondary)
m
Pumps
m
o Rolairtrol
n
Return
Water
Temperature
Zone Bias
Control Valve
T2
C
h
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T1
Common
T3
T3
3D Valves
C
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T1
T2
T2
T2
VPF Application
Zone 1
Zone 2
Zone 3
Terminal
Unit Balance
Valve
Terminal
Unit Control
Valve
Zone 4
Zone
(Tertiary)
Pump
Zone Supply
Temperature
T1
T1
Chiller Supply
Temperature
T3
GPX
Flow
Meter
Common
C
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Common
T3
Zone
Balance
Valve
Rolairtrol
Return
Water
Temperature
Zone Bias
Control Valve
T2
C
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T1
Common
T3
T3
3D Valves
C
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T1
T2
T2
T2
Comments?
Questions?
Observations?
Zone A
C
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C
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Zone B
Supply
Return
Zone C
Shared Piping
Zone A
C
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C
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Zone B
Supply
Shared Pipe
Return
Zone C
Shared Piping
Zone A
C
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C
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Zone B
Supply
Shared Pipe
Return
Zone C
Flow :
Current = 3000
Future = 4500
C
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C
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Zone A
1500 gpm
(1500 gpm)
Zone B
Zone C
Supply
Current = 1500
Future = 3000
Current = 0
Future = 1500
Return
Future Zone C
Zone A Requirements
(1500 gpm)
Zone A
Zone B
Zone C
4500 gpm*
A1 Supply
A2
A Zone A
Pressure drop:A to A1+B to B1
Present = 20.8
*Future = 45.2
B1
Return
B 4500 gpm*
A3
B2
B3
Zone A Calculations
Table 9-1 Zone A calculations
Zone A (A to A1 + B to B1)
Pipe Size
Pressure Drop - ft / 100 ft
Equivalent Length
(supply & return)
Pressure drop
Zone pressure drop
Total pressure drop
1000 ft x 2 = 2000 ft
45.2 ft
80 ft
125.2 ft
1000 ft x 2 = 2000 ft
20.8 ft
80 ft
100.8 ft
Zone B Requirements
(1500 gpm)
Zone B
Zone A
4500 gpm*
A
3000 gpm*
A1 Supply
B 4500 gpm*
Zone C
A2
Return
3000 gpm*
A3
B2
B3
Zone B Calculations
Table 9-2 Zone B calculations
Zone B(A1to A2+B1 to B2)
Pipe Size
Pressure Drop - ft / 100 ft
Equivalent Length
(supply & return)
Pressure drop
Previous pressure drop
Zone pressure drop
Total pressure drop
1000 ft x 2 = 2000 ft
33.4 ft
45.2 ft
80 ft
158.6 ft
1000 ft x 2 = 2000 ft
9.0 ft
20.8 ft
80 ft
109.8 ft
Zone C Requirements
1500 gpm @ 80 1500 gpm @ 80
Zone B
Zone A
4500 gpm
A
1500 gpm
3000 gpm
A1 Supply
Zone C
A3
A2
B1
B 4500 gpm
1500 gpm @ 80
Return
3000 gpm
B2
B3
1500 gpm
Zone C Calculations
Zone C (A2 to A3 + B2 to B3) Future Flow @ 1500 gpm
Present Flow @ 0 gpm
Pipe Size
10
Pressure Drop - ft / 100 ft
1.07
Equivalent Length
(supply & return)
1000 ft x 2 = 2000 ft
Pressure drop
21.4 ft
Previous pressure drop
78.6 ft
(A to A2, B to B2)
Zone pressure drop
80 ft
Total pressure drop
180.0 ft
Pump Selection @ 1500 gpm 1510-6G @ 82.7 hp = 125 hp*; Note: 50 hp more
than Zone A
Present Requirement
Future Requirement
Duty Pump Standby Pump Duty Pump Standby Pump
1 @ 75 hp
1 @ 75 hp
1 @ 75 hp
1 @ 75 hp
1 @ 100 hp
1 @ 100 hp 1 @ 100 hp
1 @ 100 hp
1 @ 125 hp
1 @ 125 hp
2 @ 175 hp
2 @ 175 hp 3 @ 300 hp
3 @ 300 hp
4 @ 350 hp
6 @ 600 hp
Zone
Pump B
Zone
Pump C
Load
Friction
Loss
0
Friction Loss
Supply Header
Friction Loss
Return Header
Primary-Secondary Equivalent
1500 GPM
1500 GPM
(1500 GPM)
A3
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
AFDs
B
3000 GPM
B1
Return B2
1500 GPM
B3
P-S Calculations
Primary-Secondary pressure drop calculation:
Pipe Segment
A to A1 + B to B1
A1 to A2 + B1 to B2
A2 to A3 + B2 to B3
Zone B
Total
Pressure Drop
Present, feet
20.8
9.0
DNA
80.0
109.8
Pipe Segment
A to A1 + B to B1
A1 to A2 + B1 to B2
A2 to A3 + B2 to B3
Zone C
Total
Pressure Drop
Future, feet
45.2
33.4
21.4
80.0
180
P-S Calculations
Distribution pump selection:
Present = 3000 gpm @ 109.8 feet, increase impeller to 13.5 for future head requirements:
2 @ VSCS 8x10x17L @ 111.0 hp 125 NOL
1 @ VSCS 8x10x17L @ 111.0 hp 125 NOL, standby
Total
3 Pumps
375 NOL, Total
Future = 4500 gpm @ 180 feet:
3 @ VSCS 8x10x17L @ 114.4 hp 375 NOL
1 @ VSCS 8x10x17L @ 114.4 hp 125 NOL
Total
4 Pumps
500 NOL
Comparison
Zone Pumping
Present
350 hp
Future
600 hp
P/S Pumping
Present
375 hp
Future
500 hp
Primary-Secondary Zone
Pumping Cautions
Excessive initial horsepower
Initial equipment investment
Future considerations
Reduced Horsepower
Comments?
Questions?
Observations?
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
AFDs
Return
Differential
Pressure
Sensor
WRONG!
Chiller 1
Chiller 2
Chiller 3
Single
Point
Pressure
Sensor
AFDs
Pump
Controller
Return
Shut-off head
Design Point
70
Constant Pressure
60
Head, FT
50
1750 RPM
(Maximum rpm)
40
30
1480 RPM
(Minimum rpm)
20
10
0
200 400
600 800
Flow, gpm
What if?
Zone A
Zone B
P Sensor here
Supply
C
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C
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AFDs
Pump
Controller
Return
Zone C
Design Point
70
60
Head, FT
50
Maximum rpm
40
30
20
Minimum rpm
10
0
200 400
600 800
Flow, gpm
Base 100
90
80
70
V/S, 25% Variable Hd Loss, 75% Constant Hd
60
50
40
30
V/S, 100% Variable Hd Loss, 0% Constant Hd
20
10
0
10
20 30 40
50 60 70 80 90
% Flow
100
Coil or Valve?
25 Head
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
AFDs
Return
Differential
Pressure
Sensor
Control Area
Zone 2
20 ft
Zone 1
20 ft
DP Sensor
C
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C
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Pump
Controller
AFDs
P Zone 1
20FT
20FT
P BC+DE P Zone 2
20FT
20FT
TDH = P AB + EF + BC + DE + P ZONE 2 = 60 FT
Control Area
60
50
40
Head, FT
30
20
Lower Limit
Upper Limit
Single Point
10
0
0
100
300
So What...?
Staging pumps in a closed loop HVAC
system by flow alone may not work
because of different head requirements
for a given flow.
Wire to water pump efficiency
calculations at part load depend heavily
on the assumptions made about the
nature and shape of the control curve.
Zone 1
25 ft
B (50)
E (10)
F
Flow Zone 2
Friction Loss
Friction Loss
Head Required
Setpoint -
AB+EF
BC+DE
Zone 2
Friction Loss
0 gpm
600 gpm
20
20
300 gpm
300 gpm
30
600 gpm
0 gpm
40
Sensor Location
Zone 2
Zone 1
DP Sensor
C
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C
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C
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Pump
Controller
AFDs
Flow
Zone 1
0 gpm
300 gpm
600 gpm
Flow
Zone 2
600 gpm
300 gpm
0 gpm
Friction Loss
Friction Loss
Friction Loss
AB+EF
Zone 1
BC+DE
5
5
5
0
6.25
25
20
5
0
P Zone1,
Available
40
25
20
Sensor in Zone 1
Zone 1 requires 600 gpm at 25 ft
Zone 2 requires 600 gpm at 20 ft
Flow Zone 1
0 gpm
300 gpm
600 gpm
Flow Zone 2
600 gpm
300 gpm
0 gpm
Friction Loss
AB+EF
5
5
5
Friction Loss
BC+DE
20
5
0
Head Required
Zone 2
20
5
0
In this system:
Single sensor in Zone 2 at 20 ft fails to
provide adequate flow only when
load in Zone 2 < 50% and
load in Zone 1 > 75%
Zone B
Supply
DP Sensors
C
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C
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AFDs
Pump
Controller
Return
Zone C
Zone 2
A
OR
E
F
Supply
C
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Return
Zone A
C
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Zone B
Zone C
C
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Return
Zone A
C
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C
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Zone B
Supply
Return
Zone C
Summary
Give priority to the needs of the branch.
The rule of sensor location is simple and easy
to apply:
If you have to use a single sensor, put it across
the critical branch.
Whats the critical branch?
Its the same one that determined the pump head.
Comments?
Questions?
Observations?
Systems Approach
Control M
Load
Distribution
Air Management
Verification
Philosophy
Source
Systems Approach
All components work together as team
Components interact and work as well as we
understand them
Hydronic Balancing
We worry about balance because:
Load calculations are approximate
Piping circuitry analysis is approximate
Control valve selection is approximate
Approximations will lead to underflow and
overflow situations
For example:
Published by
ASHRAE &
Hydraulic
Institute
DarcyWeisbach
Equation.
Add 15%!
What Is Balancing?
Its test, adjust & balance
Test: The system, now built, is verified in
operation to perform to the expected level.
What do we measure?
temperature, flow, pressure drop, energy
consumption.
Adjust
Adjust: tested in operation, the system is
found lacking and needs fine tuning.
What level of adjustment, and for what
purpose?
Create comfort conditions
Minimize energy consumption
Prevent equipment damage
How do we adjust?
Balance
Balance is often interpreted to mean 10%
of design flow.
This generalization may or may not yield
satisfactory heat transfer required for
comfort conditions
Redefining Balance
Evaluate System Operation
If the goal is occupant comfort, then heat
transfer becomes the key concern.
We control heat transfer as a sensible
temperature control process between controller,
control valve and coil
Analysis should account for interaction of all key
components, and how they affect the rest of the
system
Total
45
40
100%
80%
30
Sensible
25
60%
Latent
40%
20
15
10
20%
5
0%
0%
20%
40%
60%
80%
100%
120%
140%
% Flow
30H X 46W 10 FPI / 4 Row 30 GPM / 10T 85 DB/ 71 WB Ent 45 EWT 15 Circuits 3/8 Tube 4000 CFM Nominal 10 Ton Rating
160%
180%
0
200%
Waterside T (F)
% Heat Emission
35
80%
100%
30H X 46W 10 FPI / 4 Row 30 GPM / 10T 85 DB/ 71 WB Ent 45 EWT 15 Circuits 3/8 Tube 4000 CFM Nominal 10 Ton Rating
97%
15%
20%
Heating
260
240
220
200
180
160
140
120
100
80
70 16
60
50
40
0
5%
Cooling
-0 / +10%
10
12
14
16
18
20
22
24
Head (Feet)
120
100
80
60
40
20
0
0
50
100
150
Flow (USGPM)
200
250
Cartridge
Cartridge Operation
Flow
Flow
P1
P2
P1 is low
Cartridge Opens
P1 - P2 = Constant
P1
P2
P1 is high
Cartridge Closes
P1 - P2 = Constant
Flow in GPM
Control Range
Design Flow
Accuracy
Range
Consider:
Branch to riser pressure
drops should be 2:1 or
General 4 -10 fps
greater
Mechanical rm. 6 -15 fps
Direct return circuits in
Maximum velocity
variable speed / variable
1500 hr/yr 15 fps
flow hydronic circuits
3000 hr/yr 13 fps
require much more
6000 hr/yr 10 fps
attention to detail and
Pressure drop
control
sequence
1.0 to 4.0 ft / 100 ft.
ASHRAE 90.1-2010
CHAPTER 6
<2000 Hours/Year
>4400 Hours/Year
Other
Variable Flow/
Variable Speed
Other
Variable Flow/
Variable Speed
Other
Variable Flow/
Variable Speed
120
180
85
130
68
110
180
270
140
210
110
170
350
530
260
400
210
320
410
620
310
470
250
370
740
1100
570
860
440
680
1200
1800
900
1400
700
1100
10
1800
2700
1300
2000
1000
1600
12
Maximum Velocity for Pipes
over 12 in. Size
2500
3800
1900
2900
1500
2300
8.5 fps
13.0 fps
6.5 fps
9.5 fps
5.0 fps
7.5 fps
<2000 Hours/Year
Nominal Pipe
Friction
Size, in.
Other Loss Rate
(GPM) (Ft/100 Ft)
120
10.01
2 1/2
180
7.26
3
350
6.55
4
5
410
2.84
6
740
3.47
1200
2.2
8
1800
1.52
10
2500
1.18
12
Variable
Friction
Speed Loss Rate
(GPM) (Ft / 100 Ft)
180
21.78
270
15.78
530
14.56
620
6.25
1100
7.44
1800
4.79
2700
3.3
3800
2.63
Other
(GPM)
85
140
260
310
570
900
1300
1900
>4400 Hours/Year
Friction
Variable
Friction
Loss Rate Speed Loss Rate
(Ft / 100 Ft) (GPM) (Ft / 100 Ft)
5.2
130
11.66
4.5
210
9.74
3.72
400
8.46
1.67
470
3.68
2.11
860
4.63
1.27
1400
2.95
0.82
2000
1.86
0.7
2900
1.57
Other
(GPM)
68
110
210
250
440
700
1000
1500
Friction
Variable
Friction
Loss Rate Speed Loss Rate
(Ft / 100 Ft) (GPM) (Ft / 100 Ft)
3.42
110
8.48
2.86
170
6.51
2.48
320
5.52
1.12
370
2.34
1.3
680
2.96
0.79
1100
1.86
0.5
1600
1.21
0.45
2300
1.01
Velocity
Operating
Hours/Year
Nominal Pipe
Size, in.
Other
(GPM)
120
2 1/2
3
180
350
4
410
5
6
740
1200
8
1800
10
2500
12
<2000 Hours/Year
Velocity
(ft/sec)
8.04
7.81
8.82
6.57
8.22
7.7
7.32
7.17
Variable
Speed
(GPM)
180
270
530
620
1100
1800
2700
3800
Velocity
(ft/sec)
12.06
11.72
13.36
9.94
12.22
11.55
10.98
10.89
Other
(GPM)
85
140
260
310
570
900
1300
1900
Velocity
(ft/sec)
5.69
6.08
6.55
4.97
6.33
5.78
5.29
5.45
Variable
Speed
(GPM)
130
210
400
470
860
1400
2000
2900
>4400 Hours/Year
Velocity
(ft/sec)
8.71
9.12
10.08
7.53
9.55
8.98
8.13
8.31
Other
(GPM)
68
110
210
250
440
700
1000
1500
Velocity
(ft/sec)
4.56
4.78
5.29
4.01
4.89
4.49
4.07
4.3
Variable
Speed
(GPM)
110
170
320
370
680
1100
1600
2300
Velocity
(ft/sec)
7.37
7.38
8.07
5.93
7.55
7.06
6.51
6.59
SYSTEM SYZER
Flow/Pressure Drop
Estimated annual
energy cost based
on pipe size
Note that cost is based on a constant load it is
independent of the info in ASHRAE frame
% Design Flow
In End Circuit
95
90
80
Head
100%
Head
100%
Flow
(USGPM)
Pipe
Size
5000
12
14
16
18
20
24
5500
14
16
18
20
24
3.33
1.7
0.94
0.54
0.22
13.04
9.99
7.89
6.35
4.39
6000
14
16
18
20
24
3.94
2.01
1.11
0.64
0.26
14.23
10.89
8.61
6.92
4.79
Reynolds
Friction
Flow Type
Number
Factor
1172764
1066660
933291
829403
743901
618839
Transition
Transition
Transition
Transition
Transition
Transition
0.014
0.0139
0.0138
0.0138
0.0138
0.0138
1173326
1026626
912343
818292
680723
Transition
Transition
Transition
Transition
Transition
0.0138
0.0137
0.0136
0.0136
0.0137
Transition
Transition
Transition
Transition
Transition
0.0137
0.0136
0.0135
0.0135
0.0136
1279992
1119949
995283
892682
742607
Balanced
Flow
Coefficient Available
CV
P
Branch
Set Point = 20 Ft
10
340
20
1000
287
28
1000
253
36
1000
229
44
1000
211
52
1000
196
60
1000
10
CV
CV
CV
e
CV
d
CV
32
Total
CV
24
4
C
16
4
D
4
A
6000@68
40
b
Branch
Flow
Branch = 20
Risers = 48
Ratio = 0.4
70.0
60.0
50.0
Head (Feet)
40.0
30.0
20.0
0.0
0.0
1000.0
2000.0
3000.0
4000.0
5000.0
6000
Flow (USGPM)
Q2
h2 h1 Min Control Head
Q1
2:1 BRPDR
70.0
10
10
CV
G
.83
F
60.0
Head (Feet)
50.0
.83
E
.83
D
40.0
.83
C
.83
B
30.0
20.0
0.0
1000.0
2000.0
3000.0
Flow (USGPM)
4000.0
5000.0
g
CV
1.7
CV
3.4
6000.0
.83
f
5.1
.83
e
.83
d
6.8
.83
3
CV
4
CV
c
CV
8.5
.83
b
.83
10.0
0.0
.83
A
a
6000 @ 30
VFD
6000 GPM
@88 Ft Hd
10
10
1
2
2
40
2
24
E
10
10
10
32
F
10
10
10
8
C
20
0
B
10
10
10
10
16
D
Valve 6 Closed
Valve 6 & 5
Closed
100.0
Valve 6,5,4,3
Closed
80.0
Valve 6,5,4
Closed
All Open
Head (Feet)
Valve 6,5,4,3,2
Closed
60.0
40.0
Valve 1 Closed
All Closed
20.0
System Curve
Inboard
Outboard
0.0
0
1000
2000
3000
4000
Flow (GPM)
5000
6000
7000
Thoughts On Selection
Coil pressure drop dominates system
controllability.
Control valve selection with = 0.5
Balancing valves: provide trim
Use as much PD as possible in control valves
Absorb the rest at the balancing valve.
Additional Resources
Questions?
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