Hydronic

Systems

BASIC HYDRONIC SYSTEM

DESIGN
Terminal Units
FCU FCU FCU FCU FCU FCU
Fan Coils, Chilled Beams,
Finned Tube, Radiant, etc.

Distribution
Piping AS-1

P-1
Decoupler
Primary Pumps ET-1
P-B-1
Closely Spaced Tees
P-1 & P-2
P-2
B-1

P-B-2

Expansion Generation Equipment

Tank Air / Dirt B-2

Secondary Pumps Boilers, Chillers, Cooling

Separator
P-B-1 & P-B-2 Towers, WWHPs, etc.

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 REFERRING TO PUMPS
FCU FCU FCU FCU FCU FCU
FCU FCU FCU FCU FCU FCU

AS-1
AS-2

P-1
P-3
P-B-1
ET-1 P-CH-1
ET-2

P-2
P-4
B-1 CH-1

Primary P-B-2
Secondary P-CH-2

Pumps B-2
Pumps CH-2

Secondary Primary
Pumps Pumps

HEATING COOLING

AIR/DIRT SEPARATORS
ƒ Air Vents at High Points
ƒ Reduce Fluid Velocity
ƒ Change Fluid Direction
ƒ Reduce Pressure (Tangential)
ƒ Coalescence (Microbubble)

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 EXPANSION TANKS
ƒ Control pressure, control problems
ƒ Expansion tanks control thermal expansion and
contraction of system fluid
z Establish the point of “no pressure change”.

Full Acceptance Partial Acceptance Partial Acceptance

Bladder type Bladder type Diaphragm type

CENTRIFUGAL PUMP
COMPONENTS
Bearing Frame Casing / Volute
Assembly
Discharge
Motor

Suction

Drain Pan

Coupler w/Guard Base

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CENTRIFUGAL PUMP
COMPONENTS
Bearing Frame Woods Dura-Flex
Impeller
Assembly Coupler

Motor
Mechanical Pump Shaft Motor Shaft
Seal

COUPLER

Woods Dura-Flex Coupler

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BEARING ASSEMBLY

Bearing Frame Assembly

MECHANICAL SEAL
Cover
Impeller

StationarySeat

Pump Shaft

Slip-on Shaft Sleeve Rotating Element

John Crane (Type 21) mechanical seal

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 END SUCTION PUMPS
ƒ End Suction Pumps
z Most Popular Style
z Suction / Discharge at 90º
z Split coupled allows servicing without disturbing
pipe connections

Base Mounted, Split Coupled Foot Mounted, Close Coupled

IN-LINE PUMPS
ƒ In-Line Pumps
z Suction / Discharge are In-Line

z Differentiated by shaft orientation

z Pipe supported, not fixed to structure

Horizontal In-Line Vertical In-Line

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 SPLIT CASE PUMPS
ƒ Split Case
z Two sets of bearings to support shaft

z Allows Access to both seals without moving motor or

disturbing piping
z Up to 1,500 HP

Horizontal Split Case Vertical Split Case

VERTICAL TURBINES
ƒVertical Lineshaft Turbine
ƒDesigned to Lift Liquid from Sump / Tank
ƒMotor and Impeller are separated
ƒImpellers “Push” better than “Pull”
ƒCooling Tower Sumps

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 NEW “SMART” PUMPS
ƒ Speed varies without sensors
ƒ High Efficiency ECM
z Electronically Commutated Motor
z A.k.a. DC Brushless Motor
ƒ Integral VFD
ƒ Sophisticated Electronics
ƒ Residential to Light Commercial

TYPICAL
CAPACITIES
TYPE GPM HD (FT.) HP RPM

HORIZ. IN-LINE 20 - 375 10 - 75 ¼-3 1760, 3500

END SUCTION 40 – 4,000 10 - 400 ⅓ - 200 1160, 1760, 3500

VERTICAL IN-LINE 40 – 12,000 10 - 400 ¼ - 600 1160, 1760, 3500

SPLIT CASE 100 – 18,000 20 - 500 3 – 1,500 1160, 1760, 3500

VERTICAL TURBINE 20 – 6,000 10 - 150 ½ - 150 1160, 1760

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 CENTRIFUGAL PUMP
FUNCTION
ƒ Pumps create Differential Pressure (ΔP)

ƒ Water Flows From Higher Pressure to Lower Pressure

ƒ The ΔP Induces Flow Against System Resistance

ƒ In an Open System the ΔP also Induces Lift Against

Atmospheric Pressure and Gravity

CENTRIFUGAL PUMP
BASIC OPERATION
ƒ Impeller spin accelerates the liquid radially
ƒ Liquid forced to the outside of the impeller
ƒ Cutwater diverts liquid out through the discharge
ƒ Impeller eye is point of lowest pressure
Discharge

Suction Impeller

Cutwater

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 CENTRIFUGAL PUMPS
AFFINITY LAWS
The Pump Affinity Laws are a series of relationships
relating:

Flow (GPM)
Head (HEAD)
Horsepower (BHP)
RPM Speed (RPM)
Impeller Dia. (DIA)

Allow designers to estimate pump performance under

different conditions

AFFINITY LAW #1
• GPM varies with RPM
• Pump speeds up, flow increases
• Pump slows down, flow decreases

• GPM varies with DIA

• Large diameter impellers move more flow
• Small diameter impellers move less flow

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 AFFINITY LAW #1

1760 RPM
60 Hz

1170 RPM
40 Hz

580 RPM
20 Hz

AFFINITY LAW #2
• HEAD varies as the square of the RPM
• Pump speeds up, head increases exponentially
• Pump slows down, head decreases exponentially

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 AFFINITY LAW #2

AFFINITY LAW #3
• BHP* varies as a cube of RPM
• Pump speeds up, BHP increases by cube
• Pump slows down, BHP decreases by cube

BHP = Brake Horsepower is the actual power required to rotate the pump
shaft. It is the portion of the motor HP that does the work.

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 AFFINITY LAWS
Reducing Speed by Half:
Change in RPM Change in Change in
Change in BHP
(or DIA) GPM HEAD
x 1/2 x 1/2 x 1/4 x 1/8

Doubling Speed:
Change in RPM Change in Change in
Change in BHP
(or DIA) GPM HEAD
x2 x2 x4 x8

AFFINITY LAWS
How much HP is required to operate a 100 HP, 1760 RPM
motor at half speed?

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 AFFINITY LAWS

RPM GPM HEAD BHP

100% 100% 100% 100%

90% 90% 81% 72%

75% 75% 56% 42%

50% 50% 25% 12.5%

25% 25% 6% 1.2%

“Getting Into the Flow”

“the application of VFDs to

constant speed pumps is now the
fastest growing segment of the
commercial pumping industry, a
trend that improves (system)
performance and efficiency…”

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 WHY VFDs on PUMPS
• Soft Start
• Same cost as a motor starter
• Gentler on motors
• Reduces inrush current

• Balancing without multi-purpose valve

• Significant energy saving opportunity

• Variable Flow
• Flow varies according to demand
• Ultimate energy savings

Pump Curves

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 Pump Curves
PUMP CAN ONLY OPERATE ON ITS CURVE
13”

12”
IMPELLER CURVES
200 11”

10”

HEAD
(FT)
100

10 0 20 0 30 0 40 0 50 0 60 0 70 0

FLOW (GPM)

System Curve

200

FLOW = HEAD²
( Y = X² )
HEAD
(FT)
100

SYSTEM CURVE
(PARABOLA)

10 0 20 0 30 0 40 0 50 0 60 0 70 0

FLOW (GPM)

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 Horsepower Curves
PUMP OPERATES WHERE SYSTEM AND IMPELLER CURVES INTERSECT

IMPELLER CURVE
10 15 20
HP CURVES
200

OPERATING POINT
HEAD
(FT)
100

SYSTEM CURVE
(PARABOLA)

10 0 20 0 30 0 40 0 50 0 60 0 70 0

FLOW (GPM)

Parallel Pumping
Correct Selection
GPM IS ADDITIVE, HEAD REMAINS THE SAME

SYSTEM
CURVE

200

2 PUMPS ON
OPERATING POINT

1 PUMP ON
100
OPERATING POINT
IMPELLER CURVES

STATIC P1 or P2 P1 + P2
HEAD

10 0 20 0 30 0 40 0 50 0 60 0

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 Parallel Pumping
Incorrect Selection
GPM IS ADDITIVE, HEAD REMAINS THE SAME

SYSTEM
CURVE

200

2 PUMPS ON
OPERATING POINT

100
P1 or P2 P1 + P2
IMPELLER CURVES

One pump running does not

intersect with system curve
STATIC Result = No Flow
HEAD

10 0 20 0 30 0 40 0 50 0 60 0

Hydronic Piping Systems

ƒ Direct Return System
ƒ Reverse Return System
ƒ Primary-Secondary Pumping System
ƒ Injection Pumping System
ƒ Series Pump System
ƒ Zone Pumping System
ƒ Single Pipe System

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 Direct Return (First In/First Out)
ƒ Advantages
ƒ Shorter Pipe Runs
ƒ Lower first cost
ƒ Lower pump head

ƒ Disadvantages
z Poor Comfort
• Does not insure adequate flow to all terminal units
z Not Self Balancing
• Balance valves and balancing required

Reverse Return
(First In/Last Out)
ƒ Advantages
ƒ Improved Comfort
ƒ Greater assurance of
adequate flow to all
terminal units all times
ƒ Self Balancing
ƒ Disadvantages
ƒ Longer Pipe Runs
ƒ Higher first cost
ƒ Higher pump head

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 Primary-Secondary
ƒ Advantages
ƒ Improved Comfort
ƒ Reduced complexity
of balancing
ƒ Lower Operating
Cost
ƒ Reduced pump horsepower by separating zones with
different loads, operating temperatures, or pipe length
ƒ Disadvantages
ƒ Increased Number of Pumps and First Cost

DECOUPLING

Distance Between Tees as Short as Possible (Tee to Tee).

Pressure Drop Between Tees Will Determine Flow in Secondary
Circuit when Secondary Pump is Off

WATER ALWAYS FOLLOWS PATH OF LEAST RESISTANCE

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 Single Pipe
ƒ Advantages
z Maximum Comfort
• Insures adequate
flow to all terminal
units at all times
z Self balancing

z Lower First Cost

• Eliminate control
valves, balance valves, balancing, pipe and fittings
ƒ Disadvantages
z Requires accounting for temperature cascade to
provide adequate capacity of terminal units.

Injection Pumping
ƒ Advantages
ƒz Lower Operating
Cost
ĥ Operate secondary
systems at optimum
operating
temperatures
ƒz Lower First Cost
ĥ Use one primary boiler system for multiple secondary
systems requiring different operating temperatures.
ƒ Disadvantages
ƒz Increased Number of Pumps and First Cost

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 Injection Pumping –
Another Look!

Zone Loop

Injection

Building
Loop

Series Pumping System

ƒ Advantages 30000 BTU/H
6.4 GPM
100°F

6.4 GPM
7 FT
6.4 GPM
12 FT

z Lower Operating IHL-1

110°F P-2 P-1

Cost 40000 BTU/H

8.5 GPM
100°F

8.5 GPM
7 FT

• Reduced pump IHL-2

110°F P-3
140°F 180°F

120000 BTU/H
horsepower by 50000 BTU/H
5.3 GPM
160°F 6.4 GPM

5.3 GPM
separating zones 180°F
7 FT

B-1
P-4
with different loads IHL-3

ƒ Disadvantages
z Increased Number of Pumps and First Cost
z Operation of Pumps Affects Flow in Other Circuits
z Pumps are not decoupled

z Increased complexity of balancing

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 Zone Pumping
ƒ Advantages 30000 BTU/H
6.4 GPM
100°F

6.4 GPM
12 FT

z Lower Operating IHL-1

110°F P-1

Cost 40000 BTU/H

8.5 GPM
100°F

8.5 GPM
12 FT

• Reduced pump IHL-2

110°F P-2
140°F 180°F

horsepower by 50000 BTU/H

160°F
120000 BTU/H
6.4 GPM

5.3 GPM
separating zones 5.3 GPM
12 FT

180°F B-1
with different loads IHL-3
P-3

ƒ Disadvantages
z Increased Number of Pumps and First Cost
z Operation of Pumps Affects Flow in Other Circuits
z Increased complexity of balancing

Single Pipe
ƒ Single Pipe System
ƒ Independent Decoupled
Secondary Circuits for all
Terminal Units
ƒ Use Circulators Instead of Valves

ƒ No Control Valves
z Control Zone Temperature with
Circulators Only
z On/Off or Variable Speed
ƒ No Balance Valves
z Self Balancing

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 Next Generation
Green Piping Systems
ƒ Integrated Piping Systems
z Heating / Cooling / Fire Protection (Condenser Water)
• Trade Names – Tri Water
z Cooling / Fire Protection (Chilled Water)
• Trade Names – Total Comfort Solution, Ultimate Comfort Systems
z Cooling / Domestic Cold Water (Chilled Water)
• Trade Names – Total Comfort Solution
z Heating / Domestic Hot Water (Hot Water)
• Trade Names – Aqua Therm, Hydro Heat, Total Comfort Solution,
Ultimate Comfort Systems
z Less Materials

Next Generation
Green Piping Systems

Single Pipe LoadMatch®

HVAC/Fire Protection
Integrated Piping Main

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Thank You!

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