Domestic Hot Water System

Prepared by : Dr.Ali Hammoud

&
Eng. Mahmoud Hammoud
1

Domestic Hot Water System

Contents

Pipe sizing and water heater storage

Hot
water
consumption
and
demands
Pumping systems and performance
Boiler types & selection
Examples

Pipe Sizing
Avoid Oversizing & Under-sizing

Oversizing
High cost extra but unnecessary
Increase heat loss from distributing piping

Undersizing
Slow or even no water during peak
demand
Variation in temperature & pressure at
outlet (obvious in mixer for shower)
High noise level
3

Supply Hot Water Pipe Sizing

In a manner similar to cold water pipe , the hot
water Pipe is sized . First of all calculate the total
fixture units (0.75 of total FU) then find the
corresponding flow in gpm and then refer to pipe
flow chart and select the corresponding pipe size.
The higher the temperature of the water, the lower
would be the limit of flow velocity.

Domestic Hot Water-return Pipe Sizing [Large

Systems]

Usually for small installation, a 0.5 or 0.75 in hot

water return will be satisfactory. However for large
installation, the heat loss from the return line
becomes a major consideration.
The following method is used to size the
return pipe.
A. Calculate the approximate total effective length of
all hot water supply + return piping.
B. Based on ASHRAE recommendation , Multiply the
calculated total length by 30 Btu/Ft (28.8 W/m)
for insulated pipe , and 60 Btu/Ft (57.6 W/m) for
un-insulated pipe to obtain the approximate heat
loss in Watt.
5

Domestic Hot Water-return Pipe Sizing [Large

Systems]
C. Divide the total heat loss calculated previously (from the
multiplication of the total effective length by 28.8 W/m ).
Refer to the basic equation and calculate the mass flow in
Kg/s. take Specific heat factor is taken as 4.18 Kj/Kg.C &
where 11C is the allowable temperature drop.
D.

Convert from Liter/sec to gpm and than determine the pipe

size of the return pipe from pipe flow-chart of the closed
system .
E. The calculated gpm is used to size the return circulated
pump flow rate.
F.

Determine the required GPM (L/s ) in each circulating loop

and size the hot water return pipe based on this GPM and the
allowable friction loss as determined above step E.

Domestic Hot Water-return Pipe Sizing [Large

Systems].

Suppose the total effective length of the supply & return hot
water pipe length is 100 m ,steel insulated pipe. It is required to
size the return pipe size .

100 x 28.8 W/m 3000 watt = 3 KW.

Power S.hc m T
The corresponding flow rate is:

4.18 m 11 C 3Kw

m 0.0656 0.07 L / s
7

Domestic Hot Water-return Pipe Sizing [Large

Systems].

Domestic Hot Water-return Pipe Sizing [Large

Systems].

If there is more than one choice, we

select the smaller pipe size
(operation costs). In condition that we
do not exceed , the pressure drop and
velocity limitations.

Pipe Insulation

Boilers, storage tanks, calorifiers,

chimneys, and hot water pipes
lose their heat when exposed to
outside air. Hence they should be
insulated

Insulation material should be noncorrosive, non-toxic, moisture

resistant,

rotand
vermin-proof,
fireresistant, light, easy to apply,
anti-weathering, durable and, in
addition possess good insulation
properties
and
low
thermal
conductivity.

Insulation
fiberglass
insulation

material could be
or
rubber
type
like armaflex which

10

Pipe Insulation

Reasons

Heat conservation.

Reduce noise.

Control
condensation.

Freeze prevention.

surface

The insulating material is

the same used in duct
insulation (Fiber glass).
11

Insulation Thickness
Thicknesses or insulation to be supplied and installed for the
various systems shall conform to the following table:
(Fiber glass thickness)
a. Conditioned air supply and return (ductwork)
1 1/2"
b. Refrigerant suction and liquid lines:
1/2"
c. Condensate drain pipes
1/2"
d. Acoustic duct liner.
1
e: Heating water pipes up to 1" diameter:
1"
f. Heating water pipes above 1 :
1 1/2"
g. Domestic hot water pipes:
1"
k. Boiler, water heater
2
L. Boiler breeching & steel chimney
2.1/2

12

Insulation Thickness

Domestic Hot Water

System
Electrical Water Heater

Water To Water Storage Heater

Boiler +Water Storage

Instantaneous Or Semi-instantaneous
Types Of Heaters
13

Electrical Water Heater Power

3/4 of the total fixture units are used for hot water

Thermostat

Hot water
Drain

1.25 "

4 bar
Pressure Releif valve

Inlet water flow ?

Electrical
power

Temp.

Electrical water heater

Cold water

1"

1"

3/4 of the total fixture units are used forc old water

1.5, 2.4, 4-5, &

9 Kw
Size of EWH
15, 20 , 30, 40,
50 , 66, 80 &1
20 gallons

Power

S .hc Kg T .
4.2 150 (65 10)

4.2 Kw
Heating time Efficiency
3 3600 0.75

Where Shc is the specific heat capacity of water ( 4.2 Kj/kg. K), Heating time or recovery period T = 3
hrs, The mass of water 150 Liters = 150 Kg., Temperature rise from 10 to 6514C.
Insulation efficiency is 75-80 %.

Electrical Water Heater

1Kcal /h = 4 Kj/h = 1.11.10-3 Kw= 1.11 W

15

Hot Water Temperature

16

Service Water Heating

For 4 bed rooms 3 bathroom , The Electrical water heater capacity is

Liters
17
As a general rule Hot 250
water
35 Liter /person/day

Service Water Heating

18

 In general, electric water heaters are fully automatic and have a

storage tank, one or more electric elements, and operating and safety
controls. The heating elements are available in a variety of standard
voltages and wattages to meet the specific requirements of the
installations.
Electrical water heater are fitted with electrical resistance ( heater)
1.5 Kw, 2.4 Kw , 4- 5 Kw, 9 Kw . They could be horizontal or vertical
type . EWH are insulated and protected by steel jacketing.
EWHs should have pressure /temperature relief valve which will
relieve excessive pressure . For high pressure EWH the use of none
-return is not recommended. In this case ,the pressure relief valve is
connected to nearest floor drain.
EWHs are controlled by thermostat which will activate the electrical
heater automatically.
Available EWHs size are 15, 20 , 30, 40, 50 , 66, 80 & 120 gallons

19

Resistance Heating Element

Usually the electrical water heaters have a primary resistance
heating element near the bottom , and possible a secondary
element located within the upper quarter or third of the tank.
Minimum wattage ratings of two element heaters are based as
follows :
For the upper unit (8 watt / liter) of the tank capacity.
For the lower unit (5 watt/liter) of the tank capacity.
For fast heating of ( 30-40-50 gal ), we take (26 watt/litter)
for each unit.
For one single element heater ,we take (26 watt/litter).

20

21

Resistance Heating Element

Location
As a rule of thumb the daily water consumption of hot water is
about 35 liters/person a day. Which is about 30% of the total
water requirement.

mass s.h.c temp.rise(t )

Heating time (sec .)
( Power (Kw)) efficiency
22

 The Electric Water Heater shown below

is a product of
Kangquan Electrical Appliance Co., Ltd., model KDE100,
capacity: 100L and power: 1600W.

23

Hot Water Demand

Definition

Demand Of Water Supply

Is the rate of flow in pgm furnished by a water
supply system to various types of plumbing fixtures
and water outlets under normal conditions.

Maximum Demand
Is the peak value of the demand. The values Hot of
water demand are shown previously in table (W-2 ).

Demand Factor
Is the ratio of the maximum demand of the hot water
heating system to the total connected load or the
total of the individual requirements of all the fixtures
of the system.
24

Water To Water Storage Heater

A hot-water storage tank must meet code requirements that
depend on its size and pressure and the authority having
jurisdiction. Its capacity should be selected so that 60 to 80
percent of the volume of water in the tank may be drawn off
before the temperature drop (caused by the incoming cold
water) becomes unacceptable. A value of 70 percent usually is
used in design calculations.
Heated water from boiler enter the coil of the water storage
vessel where it will heat the water , and then returns to boiler
at lower temperature . Whereas the domestic Hot water leaves
the top of the water tank to the supply distribution piping upon
demand for the various fixtures and apparatus. When
recalculation of the hot water is provided, the warm water is
returned to the bottom of the hot water vessel or tank by a
circulate pump.
Normally heating water from boiler enters the water tank at 180
F ( 82 C ) and return to boiler at 160 F ( 70 25C), T = 12-15
C.

Hot Water Requirement For

Storage

The hot water storage for Buildings &

Hotels will be calculated based on unit
hourly demand rates as follows :
Gallon Per Hour
Fixture type Building
Hotels

Lavatory

2 gph

gph
bathtub
20 gph
30 gph

20 gph
Shower
26
75 gph

27

28

Procedure For Estimating The Heating Capacity

(Recovery Capacity) Of A Hot-water Heating System
Having A Storage Tank.

Step(1) Tabulate the number of fixtures of each type in the

building.
Step(2) Then multiply the number of fixtures of each type by the
probable demand for each type of fixture.
Step(3) Obtain the maximum demand by taking the sum of
products of step (2)
Step(4) Then obtain the hourly heating capacity by multiplying
the maximum demand in step3 by the demand factor obtained
from table 2.
Step(5) Multiply the hourly heating capacity of step 4 by the
storage capacity factor given in table HW-1 for the appropriate
type of building to obtain the required capacity of the storage
tank.
29
N.B. Not to be used for instantaneous
instantaneous types of heaters.

or

semi-

Example
Suppose you have to calculate , the hot water storage capacity ,
the boiler power of an apartment house (building) having the
following data:
60 Lavatories , 40 kitchen sinks ,and 10 laundry 60 showers, and
40 dishwasher .
Step 1&2
The probable water demand are as follows:
From table HW-1;
Lavatories

= 60 x 2 gph

= 120 gph

Kitchen sink

= 40 x 10 gph

= 400 gph .

Laundry

= 10 x 20 gph

= 200 gph .

Shower

= 60 x 30 gph

= 1800 gph.

Dishwasher

= 40 x 15 gph

= 600 gph .

30

Example cont.
Step 3
The Maximum demand of the hot water demand is:
=((602gph)+ (6030gph)+ (4010gph) + (40 x 15 gph) +(10x 20 gph ))= 3120
gph.
Step 4
Building demand factor = 0.3 (from table HW-1 ).
Hourly heating capacity = (31200.3) = (936 gph)= 15.6 gpm.= 0.985 liter /sec
or 3546 L/hr.
Step 5
The required capacity of the storage tank is:
Usable capacity = 936 x 1.25 = 1170 gal i.e. (4429 liters)
[1.25 is the storage factor from table Hw-1]
Safety storage
Since only 70% of the tank is usable, so the actual tank capacity = (1170 / 0.7
gallon) = (1670 gallon) that is (6327 liters).
31

Program
Given
60 Lavatories , 40 kitchen sinks ,and 10 laundry 60 showers, and 40
dishwasher

32

Program

From the basic equation Q = m

C T

33

Boiler Power Calculation

Boiler

Power

Q (BTU/h)=GPM(60min/hour)T(8.3
1
Q (boiler in BTU/h) =
Wher gpm
T

lb/gal )

500

gpm

T1

= Calculated

water

demand in

= Temperature

difference

between

initial

gpm

(flow

& Fianal

rate

[ 20 F=11 C

From the previous example: T=20 F

we have 936 gph = 15.6 gpm of water to be heated , temperature rise
T=20 F.
QT= 500 x 15.6 x 20 = 156000 BTU/hr
34

Acceptable Temperature Of Domestic

Hot Water

F = 1.8 C + 32 , C = 0.55 (F - 32)

35

Boiler Power
1 Kw = 860 Kcal/hr. = 3413 BTU/ hr.
1boiler Hp = 9.81 KW.
The required gross boiler power for heating water + overcome
the heat loss from pipe and boiler + the heat needed to rise the
initial water temperature ( Pick up ) is given by:
QBoiler = QT [1+ a + b]
QT = Calculated boiler power+ heating domestic water
a = additional heat coefficient to overcome the heat loss in the
pipe systems and boiler. [0.1]
b = additional heat coefficient to overcome the pick up period
[0.1 to 0.2] . The required gross output is then;
QBoiler = [1.2 or 1.3 ] QT
As mentioned before : for QT= 230 Kw ,

36

Boiler Power

37

Hot Water Pumps

Pumps used in hot water primary and secondary distribution
systems are used mainly for maintaining or increasing the rate
circulation. Pumps are constructed to withstand the high
temperature of water. They have a cast-iron body and a gunmetal impeller. Impellers made of other materials, such as
bronze , stainless steel and cast iron are also used.
Hot water pump is recommended to be located in the return
side of the pump to reduce the possibility of cavitation .
In well-designed systems, frictional loss in pipe-lines during
recirculation is quite low and the pump horse power is also
small .Hot water recirculation pumps should never be
used as booster pumps to increase the pressure in the
hot water system, as this creates imbalance in the
pressures of hot and cold water supply.
38

Hot Water & Boiler Circulated

Pumps
There are two centrifugal
circulated pumps used in Hot
water system:
Pump1 (primary): Is used to
circulate the hot water from
boiler to storage tank (closed
system).
Pump2 (secondary): is used to
circulate the hot water system
(Located in the returned pipe ).

Circulating pump is controlled by an immersion thermostat (in

the return line) set to start and stop the pump over a 11 C).
However for continuous hot water supply the thermostat is
39
eliminated.

The Calculation Of The Closed Loop

Circulated Pump
From the roof

P T

BOILER
KW

P.R.V.

Hot woter

Q= gpm
h=6 m

Return hot water

FUEL Supply
Expansion Vessel
100 L

40

Hot Water Circulating Pump

( Inside The Apartment)

If water heater is located far away from plumbing

fixtures (more than 20-30 m) hot water circulator
might be provided in order to have hot water in the
piping system all the time and not to wait for a long
time to have hot water.
To size the hot water circulator 1st calculate the
total hot water fixture units (as mentioned for cold
water ). Normally hot water fixture unit is 0.75 of
total fixture unit.

41

Example
Suppose we have a large flat having the following plumbing
fixtures estimate the circulated pump discharge in gpm :

4
4
2
4
2

showers
lavatories
bath tubes
bidet
sinks
Total

x 2 x 0.75
x 1 x 0.75
x 2 x 0.75
x 2 x 0.75
x 2 x 0.75
_________
= 21 FU

=
=
=
=
=

6
3
3
6
3

As a rule of thumb For every 20 FU provide 1 gpm of

circulation 21 FU/ 20 FU = 1.05 gpm .
Pump head is calculated by multiplying pipe effective length by the pressure
drop per 100 ft as discussed earlier including pipe fittings.
42

Hot Water Circulating Pump

( Inside The Apartment)

For hot water systems in which piping from the heater

to the fixture or appliance is short [(30 m), or less],
circulating systems are not generally used. But it is
common practice to provide circulating pump in all hot
water supply systems in which it is desirable to have
hot water available continuously at the fixtures.
Sizing of hot water circulating pump is simplified by
1 gpm for every 20 fixtures units in the system.

43

Calculation Of Circulating Pump

-1 Capacity

Circulating
pump 2

H.W. S
R.H.W.

H.W.Storage tank

H.W. S
R.H.W.
Circulating pump
C.W.S

44

Suppose We Have A Building Containing The

Following Plumbing Fixtures Estimate The Circulate
Pump-1 Flow Rate In gpm
Lavatories

= 60 x 1 x 0.75

= 45 Fus.

Kitchen sink

= 40 x 2 x 0.75

= 60 Fus .

Laundry

= 10 x 2 x 0.75

= 15 Fus .

Shower

= 60 x 2 x 0.75

= 90 Fus.

Dishwasher

= 40 x 1 x 0.75

= 30 Fus .

-----------------------Total

= 240 FU

For every 20 FU provide 1 gpm of circulation 240 FU/ 20 FU = 12

gpm
This is the discharge of the circulated pump , which circulate the
water from (boiler tank) to building.

45

Calculation Of The Circulating Pump

-2 Capacity
Pump 2

P T

P.R.V.

H.W.Storage tank

H.W. S
R.H.W.

BOILER

Boiler
Circulating pump

FUEL Supply

Circulating pump
C.W.S

Expansion Vessel

T=20 F =11 C

Pump 1
46

Estimating Circulating Pump 2

Capacity

In U.S.units
The GPM of the system Circulating pump ;
Q (BTU/h) GPM (60min/hour) T1 (8.3 lb/gal)
Q (gpm) Q (boiler in BTU/h) / (8.3 T1 60min/hour)
Q (boiler in BTU/h) /500 T1
In SI units

Power KW

Kg/sec. 4.2Kj/Kg.C (11) C

Power Kw
227
Kg/sec

4.9 L/s
4.2 11
4.2 11
This is the discharge of the circulated pump 2, which circulate
the water from boiler-storage tank- Boiler
47

Head Of The Circulated Pump

As it is known that , the role of the circulated pump is
to overcome loss due to pipe friction & fittings.

hA hL p
The elevation difference is not included .
The head loss due is determined from Darcy
equation or Hazzen William equation.
F = 1.8 C + 32 , C = 0.55 (F - 32)

48

Example

Suppose we have to estimate the head required of a circulated

pump , assuming the following : The pipe length is 600 ft. and
an allowance for fittings on straight pipe of 25 %-50 % is to be
use.

1- Determine, the total effective length E.L that is:

The actual pipe length
L eff . + LEquivalent
L e length (due to fittings and
valves etc.)

2- The total head loss or pressure drop hL is determined as :

The head loss per unit of length h1(5-7ftw./100ft ) multiplied
Le ff L 25% L 600 150 750 ft
by the effective length .

hL Leff . 5 ft / 100 ft 750 0.05 37.5 ft that is [ 11 m ]

Usually the Pump is oversized by 10 % of head &49 5% flow

Expansion Tank Capacity

F = 1.8 C + 32 , C = 0.55 (F - 32)

50

Sealed Heating System

Closed- Expansion Tank Capacity

51

Sealed Heating Systems. ClosedExpansion Tank

In the sealed system of heating ,the open expansion tank and
feed cistern is replaced by a flexible- membrane expansion
vessel. The vessel may fitted near the boiler , either on the
supply flow or return pipe.
The expansion vessel must be sized so that its volume is at least
equal to the volume of expansion of water in the system, when
raised from 10 to 95 C, irrespective of the normal working
temperature.
Where
E = expansion of water m3
VS = volume of water before being heated m 3 in the boiler+
system
1 = density of water before being heated Kg/ m 3 ,T1=10C
1 2
3
2 = density
after
being
heated
Kg/
m
,T2=95) CVs
E of
Vswater

E (0.04 -0.06

52

Roof Booster Pump Calculation

Down feed (F32)

eff

L Le

hL h1 Leff 11 ft / 100 Leff

hst 6m

120 ft 36m

Leff 15 36 51m

hl 51 11m

100m
hA hst hl P
P is the surplus pressure required
to operates the fixture (shower)= 8 m
BAU 2012

5.61m

hA 6 5.61 8 7.6m
Q 19 gpm

53

Hot water Expansion Vessel Size

Selection
90 oC
1.0359
e
1
1 0.04
10 oC
1.00027
e The expansion coefficient for water heating from 10 to 90 oC

90 oC 1.0359 Liter / Kg Is the spesific volume of water @ 90 oC

10 oC 1.00027 Liter / Kg Is the spesific volume of water @10 oC

Vacc e x Vs 0.04 Vs
Vacc Accepted volume Liters
Vs Total water volume in the heating system
54
(Boiler , Pipes & Radiators) in liters

Hot water Expansion Vessel Size

Selection
The Total volume of closed expansion tank with a
bladder is calculated from Boyles Law :

Vtotal

Vs e

Pmin
1
Pmax

Pi = initial static pressure above the vessel i.e charge pressure (absolute) of
vessel. This pressure must not be lower than the hydrostatic pressure at
the point where the tank is connected to the system.
Pf= maximum operating pressure (absolute) of the relief (safety) valve,
taking into account any differences in level between the vessel and the safety
valve. (around 4 bar gage )
55

Example
Pi = initial static charge pressure
(absolute) of vessel. This pressure
must not be lower than the
hydrostatic pressure at the point
where the tank is connected to the
system
As a rule of thumb 13 liters for every 1000 w of
boiler output .
For Example 350 kW , water in the heating
water system W= 4500 Liters
Let say 15 m from technical floor to boiler room
P1= 15+10 =25 m (initial static charge pressure
(absolute value) that is 2.5 Bar
P2= around 4 bar gage +1 bar =5 Bar

Vtotal

W e
4500 x 0.04

350 liters
Pmin
2.5
1
1
Pmax
5

56

Expansion Tank Capacity Types

57

Open-Expansion tank capacity

The volume of the expansion tank is given by :

Volume of the expansion tank

0.03 Q Boiler (Kcal/h)

[in liters ]

T 12 C

The volume of the expansion tank with respect to its boiler power
Kcal/
hr.

20
000

30
000

60
000

100
000

200
000

Kw.

23

35

70

116

232

Volu
me L

50

75

100

150

200

58

Open Expansion tank pipe

diameter
The pipe diameter of the expansion tank is given by :

Pipe diameter 15 1.5

Q Boiler (Kcal/h)
1000

[in mm]

It is not recommended to use pipe diameter less than 1 inch.

Q = m C T
The relation between Water temp erature , flow rate , and
heat loss or gain is given below :
Q (BTU/h) gpm (60min/hour) TF (8.3 lb/gal) BTU/lb - F
Q (BTU/h) 500 GPM TF
The gpm of the system ;
gpm Q ( BTU/h) / 500 TF , [In U.S.units]
This eqauation can be used to determine the boiler power,
Radiator capacity , fan coil heating or cooling capacity.

60

Drawing Of Water
Distribution Systems

61

62

63

Boiler Selection And

Specifications

64

Expansion of Pipe material

L L T
L = Amount of change in pipe length, mm
= Coefficient of linear expansion, mm/m. C ( for
(API ) PPr
= 0.15 mm/m C)
T= Temperature difference , C
L = is the original length of pipe m
For example : A 6 m copper pipe is subjected to
temperature difference of 50 C
Calculate the pipe expansion L :
65
L = 0.15 x 6 x 50 =45 mm

Expansion of Pipe material

66

Calculate the length of the Arm Ls ,assuming that D=

25 mm & L =45 mm.

Ls 30 25 45 10 cm

67

Calculation Of The Arm Length Ls

68

Determination Of The Width Between

The Arms B

69

Determination Of The Width Between

The Arms B

B= 200 +2 x L =200+ 2x45 = 290 mm.

70

71

72

73

74

75

76

77

References
1Mechanical
&
electrical
equipment
for
Stein/Reynolds, Ninth edition, John Wiley, 2000.

buildings

by

2-Practical Plumbing Engineering, Cyril M.Harris, ASPE,1998.

3- Building Services & equipment (I/II/III), F.Hall, Third edition, 1994.
4- Upland
Hammoud.

engineering,

Mechanical

consulting

office,

5- Applied hydraulics Part I & II .Lecture notes." by

BAU- 1995
6- Pumps with practical
Hammoud BAU- 1999.

applications,

.Lecture

Dr.

Ali

A. Hammoud

notes.

by

A.

7- Lowara catalogue
8- Plumbers & pipefilters , Calculations Manual by R. Dodge
Woodson.
9- Plumbing Design & practice by S G Deolalikar
10- fluidedesign Jacques Chaurette
12- Internet web sides
13- Faber & Kells Heating Air-conditioning of Buildings Ninth edition
78
India-2002

Questions

79

Thank You

80