PPT-ASHRAE Hong Kong-Fundamentals of Water Systme Design

ASHRAE Hong Kong Chapter Technical Workshop
Fundamentals of Water System Design

17, 18, 24, 25 January 2007
2007 ASHRAE Hong Kong Chapter
Slide 1
Chapter 7: Piping System Development
Piping System design Direct Return Analysis Reverse Return Analysis Primary-Secondary Analysis Type of Pumps and Valves Primary-Secondary Application Study Antifreeze Solutions for Low Temperature Application Pumping Design Factors
Slide 2
Piping System Design
Slide 3
Piping System Design Flowchart
Slide 4
Typical Building Layout

Building usage Hotel Shopping Mall Services apartment Office Mechanical floor
Slide 5
Slide 6
Determine Loads and Consult References
Slide 7
Slide 8
Determine the system to be used and develop a concept for part-load control
System FCU + PAU VAV system AHU (all air system) others Plantroom Water cooled chillers Air cooled chillers Split system
Control Application Operation hour Zone IAQ/Energy consideration O&M Maintenance and Services
Slide 9
Slide 10
Develop Piping/Pumping System Concept

Water distribution system Direct return Reverse return Direct + reverse return
Chiller combination Full load/Part load/ Emergency Standby
Pumping system Primary Secondary Variable Primary sys

2007 ASHRAE Hong Kong Chapter Slide 11
Slide 12
Slide 13
What is Direct Return and Reverse Return?
Coil
Coil
Coil
Coil
Coil
Slide 14
What is Direct Return and Reverse Return?

Direct Return
Coil
Coil
Coil
Coil
Coil
Coil
Coil
Coil
Coil
Coil
Reverse Return
Slide 15
Load System Example
Slide 16
Piping Detail at Load Coil
Slide 17
Friction Loss, Medium Steel Pipe
Slide 18
Direct Return Piping Layout
Slide 19
Direct Return System

C' C Unit 2
Piping pressure drop Unit 1 Unit 2 Unit 3 Unit 4

F
B' B A Flow Unit 1
80 kPa 98 kPa 108 kPa 90 kPa
Unit 4 E
E'
Unit 3 D D'
Slide 20

Piping pressure drop and flow
C' C Unit 2
B' B A Flow F Unit 4 E E' Unit 1
Unit 1 Unit 2 Unit 3 Unit 4
5.8 5.2 5 5.5
L/s L/s L/s L/s
Design flow: 5L/s

Unit 3
Assume coil pressure drop: 30kPa

D D'
Slide 21

Piping pressure drop and flow Unit 1 Unit 2 Unit 3 Unit 4
B' B A Flow F Unit 4 E E' Unit 1
C' C Unit 2
6 5.3 5 5.6
L/s L/s L/s L/s
Design flow: 5L/s

Unit 3
Assume coil pressure drop: 15kPa

D D'
Slide 22
Reverse Return Piping Layout
Slide 23
Reverse Return System
Unit 1
Unit 2
Unit 3
Unit 4
B'
C'
D'
E'
Piping pressure drop and flow Unit 1 Unit 2 Unit 3 Unit 4 139 kPa 5.36 160 kPa 5 160 kPa 5 139 kPa 5.36 Total 20.72 L/s L/s L/s L/s L/s
Design flow: 5L/s Assume coil pressure drop: 30kPa
Slide 24
Unit 1
Unit 2
Unit 3
Unit 4
B'
C'
D'
E'
Piping pressure drop and flow Unit 1 Unit 2 Unit 3 Unit 4 124 kPa 5.41 145 kPa 5 145 kPa 5 124 kPa 5.41 Total 20.82 L/s L/s L/s L/s L/s
Design flow: 5L/s Assume coil pressure drop: 15kPa
Slide 25
Comparison
Coil Pressure drop = 30kPa

flow Unit 1 80 kPa 5.8 Unit 2 98 kPa 5.2 Unit 3 108 kPa 5 Unit 4 90 kPa 5.5 Total 21.5 Pump kw = 2.3 kw
L/s L/s L/s L/s L/s
flow Unit 1 139 kPa 5.36 Unit 2 160 kPa 5 Unit 3 160 kPa 5 Unit 4 139 kPa 5.36 Total 20.72 Pump kw = 3.3 kw
L/s L/s L/s L/s L/s
flow Unit 1 Unit 2 Unit 3 Unit 4 65 83 93 75 kPa kPa kPa kPa Total 6 5.3 5 5.6 21.9 L/s L/s L/s L/s L/s Unit 1 Unit 2 Unit 3 Unit 4 124 145 145 124
flow kPa 5.41 kPa 5 kPa 5 kPa 5.41 Total 20.82
L/s L/s L/s L/s L/s
Pump kw = 2.1 kw
Pump kw =3.1 kw
Slide 26
Piping Detail: Load Coil PrimarySecondary
Slide 27
Primary-Secondary Piping
Slide 28
Primary/Secondary system
flow Unit 1 Unit 2 Unit 3 Unit 4 kPa 8 L/s kPa 5.8 L/s kPa 5 L/s kPa 6.6 L/s Total 25.4 L/s Primary Pump kw = 1.9 kw Secondary Pump kw = 4 x 0.2 = 0.8 kw Total Pump kw = 2.7 kw
Compare to direct return system, pump kw = 2.1 kw
47.3 65.3 75.3 57.3
Slide 29
Purpose of Pumping Systems
Transport sufficient water through the piping system at the minimum differential pressure that will satisfy all connected loads at different load conditions
Slide 30
Why balanced flow is important?
Drawback of unbalanced system: Cannot meet the design flow and capacity at the air terminal unit Waste energy Short circuit (hydronic) Chiller hunting
How to balance the system?
Add Balancing Device

Fixed orifice Manual balancing valves Constant flow valve Pressure Independent control valve
Remember
Flow rate Q = Cv A P
Slide 32
Method 1 & 2 The manual balancing valve (Similar as orifice)
Is an adjustable orifice - not a flow controller. Must be manually adjusted according to pressure differential. Introduces manual error into system performance.
Slide 33
The manual balancing valve adjustment

Requires special equipment and training on procedure. Have to access valves on-site in ceilings etc. Commissioning after installation, system filling, & pump commissioning. Requires time for commissioning. Difficult to re-balance if the project completion will be in staged or modified
Slide 34
The manual balancing act

As a manual valve is adjusted, it not only changes the coil flow, it changes the total flow in the common pipe. The pressure differentials and flows across parallel circuits are upset and then must be re-adjusted.
It will be a static system, cannot response to a dynamic or variable flow system
Pressure differential & flow across the valve increased
1
Valve throttled & flow reduced
+
Slide 35
Common pipe flow & pressure loss will be reduced
Branch and risers in Manual balancing system
Dont forget those additional regulating valves:
Branches Risers
Slide 36
Method 1 & 2 The manual balancing valve (Similar as orifice)
After commissioning or adjustment of the manual balancing valves, the Cv and A (area) of each valve is fixed. The flow rate will then be pressure dependent.
Slide 37
Method 3 Constant Flow valve

Characteristic
Below the control range the cartridge is a fixed orifice & flow can be varied by a 2 way control valve In the dP control range, flow is limited to design +/-5%
Differential Pressure (dP) Range Maximum kPaD
Range Minimum kPaD 0 0 Flow Design Maximum

Slide 38
By using constant flow valve

PRO Less valves (not required in branch and riser) Reduce T&C work and time CON Flow modulating depend on control valves in part load Not fully dynamic balancing system
Either in 2-way or 3-way control valves system
Slide 39
Method 3 Constant Flow valve

After installation of the constant flow valves, the (Cv A) of each valve will compensate the variation of the (P). The flow rate will then be kept constant.
However, it is suitable for the constant flow application like, Constant flow chillers and pumps Most of the FCU application (constant flow)
Slide 40
Method 4 Pressure Independent Control Valve
Pressure independent control valve Function:1. System pressure independent 2. Flow rate Modulating control 3. Pre-set maximum flow
Pressure Independent Control Valve Characteristic

valve will then hold the flow rate constant regardless of the change in pressure differential.
Flow rate varies according to the temp controller or DDC input signal (2-10V or 4-20mA)
Pre-set Maximum flow for each AHU

Slide 42
System using Pressure Independent Control valve

Characteristic
Less valves, combine the control function. Elimination of branch balancing valves & reverse return pipe work. Valve authority = 100% Pre-set the max flow of each AHU and save lot of time in commissioning work. No need to re-balance the system even the project is staged or modified.
Slide 43
Method 4 Pressure Independent Control Valve
Flow rate Q 1%
Q 100% = (Cv A)
1-100
After installation of the pressure independent control valves, the (Cv A) of each valve will compensate the variation of the (P) at various load at any time. The flow rate will then be pressure independent, only temperature / load dependent
It is suitable for most of the modulating control applications, AHUs Precise flow control FCUs
Slide 44
What happen when the system is in part load?
The pumping system will be required to operate under various load conditions Variable flow system differential pressures throughout the system will be dynamic. Hydronic systems should be hydraulically modeled to design for full load and part load performance
Slide 45
System at Part load
60% load
Coil
83% load
Coil
31% load
Coil
100% load
Coil
Flow rate required for each AHU or branch is varying all the time
F OF
Coil
Slide 46
What happen in typical Control valve for part load condition
Valve must be perfectly sized to provide exact resistance for pressure differential when fully open to provide design flow
Slide 47
Typical Control valve for part load

Typical Control Valve is Pressure Dependence
Standard 2 way valves vary opening area only but not flow. As pressure differential varies, the flow varies.
Q = dP * Orifice constant
Slide 48
Control valve for part load

Once below design flow, as each 2-way control valve reduces flow, it increases the pressure differential and flows across parallel circuits.
System pressure varies affect the flowrate passing through valves and coils The temperature is then altered due to the pressure fluctuation.
Time
A system using typical control valve and manual balancing valve

480 PRESSURE kPa
310 kPa
262 kPa
82 kPa
0 PUMP Coil #1 REMOTE LOAD
VFD
6.3 L/s 35 kPa 35 kPa 192 kPa
DP
6.3 L/s 35 kPa 35 kPa 12 kPa
Coil
Coil
Typical control valve Manual balancing valve 2007 ASHRAE Hong Kong Chapter Slide 50
A system using typical control valve and manual balancing valve PRESSURE DROP OF CONTROL VALVE AND MANUAL BALANCING VALVE AT VARIOUS LOAD CONDITIONS
Full Flow 75% Flow 50% Flow 25% Flow 10% Flow
Branch Flow (L/s)
6.3
4.7 262 19 109 134
3.2 262 9 48 205
1.6 262 2 12 248
0.6 262 0.7 2 259

As P across typical control valve increase seriously during part load Waste energy
Branch P (kPa) 262 Coil P (kPa) 35
Manual, Balancing Valve 192 P (kPa) Control Valve 35 P (kPa)

Slide 51
Balancing Considerations
in Variable Flow Systems
Too large a balancing valve pressure

drop will affect the performance and flow characteristic of the control valve.
ASHRAE 2003 Applications Handbook, page 37.8
Slide 52
Balancing Considerations in Variable Flow Systems
Options to Consider

No manual balancing valves at coils Automatic differential pressure control to reduce differential pressure Pressure-independent control valves (with Flowrate pre-set function)
Options NOT to Consider:
Balancing valves for variable speed pumps
Slide 53
Four-Zone Heating System
Slide 54
Typical Building Layout

Building usage Hotel Shopping Mall Services apartment Office Mechanical floor
Slide 55
Primary-Secondary Pumping, FourZone Heating System
Slide 56
Primary-Secondary Bridge Energy
Slide 57
Primary-Secondary Pumping, FourZone Heating System
Slide 58
Coil With Glycol Heat Exchanger and Pump
Slide 59
Pumped Coil With Face-Bypass Dampers
Slide 60
Specific Heats of Aqueous Ethylene Glycol
Slide 61
Specific Heats of Aqueous Propylene Glycol
Slide 62
One-Shot Chemical Feeder
Slide 63
Thank you
Edward Tsui Email: kcedward@intelligent-net.com


PPT-ASHRAE Hong Kong-Fundamentals of Water Systme Design

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PPT-ASHRAE Hong Kong-Fundamentals of Water Systme Design

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ASHRAE Hong Kong Chapter Technical Workshop

Fundamentals of Water System Design

2007 ASHRAE Hong Kong Chapter

Chapter 7: Piping System Development

2007 ASHRAE Hong Kong Chapter

Piping System Design

2007 ASHRAE Hong Kong Chapter

Piping System Design Flowchart

2007 ASHRAE Hong Kong Chapter

Typical Building Layout

2007 ASHRAE Hong Kong Chapter

Piping System Design Flowchart

2007 ASHRAE Hong Kong Chapter

Determine Loads and Consult References

2007 ASHRAE Hong Kong Chapter

Piping System Design Flowchart

2007 ASHRAE Hong Kong Chapter

Piping System Design Flowchart

2007 ASHRAE Hong Kong Chapter

Develop Piping/Pumping System Concept

Chiller combination Full load/Part load/ Emergency Standby

Pumping system Primary Secondary Variable Primary sys

Piping System Design Flowchart

2007 ASHRAE Hong Kong Chapter

Piping System Design Flowchart

2007 ASHRAE Hong Kong Chapter

What is Direct Return and Reverse Return?

2007 ASHRAE Hong Kong Chapter

What is Direct Return and Reverse Return?

2007 ASHRAE Hong Kong Chapter

Load System Example

2007 ASHRAE Hong Kong Chapter

Piping Detail at Load Coil

2007 ASHRAE Hong Kong Chapter

Friction Loss, Medium Steel Pipe

2007 ASHRAE Hong Kong Chapter

Direct Return Piping Layout

2007 ASHRAE Hong Kong Chapter

Direct Return System

Piping pressure drop Unit 1 Unit 2 Unit 3 Unit 4

B' B A Flow Unit 1

80 kPa 98 kPa 108 kPa 90 kPa

2007 ASHRAE Hong Kong Chapter

Direct Return System

B' B A Flow F Unit 4 E E' Unit 1

Unit 1 Unit 2 Unit 3 Unit 4

80 kPa 98 kPa 108 kPa 90 kPa

5.8 5.2 5 5.5

L/s L/s L/s L/s

Design flow: 5L/s

Assume coil pressure drop: 30kPa

2007 ASHRAE Hong Kong Chapter

Direct Return System

65 kPa 83 kPa 93 kPa 75 kPa

L/s L/s L/s L/s

Design flow: 5L/s

Assume coil pressure drop: 15kPa

2007 ASHRAE Hong Kong Chapter

Reverse Return Piping Layout

2007 ASHRAE Hong Kong Chapter

Reverse Return System

Design flow: 5L/s Assume coil pressure drop: 30kPa

2007 ASHRAE Hong Kong Chapter

Reverse Return System