TM 4.3.31 page 1 COOLING WATER TREATMENT Jan 94 rev3 a WATER TREATMENT OF EVAPORATIVE COOLING WATER SYSTEMS Gonsral” Evaporative cooling water systems, control:- .9, Cooling Towers) must have water treatmant to 1. Sludge build-up, 2. Scaling/eorrosion of pipe-work and equipment. 3. Micrd-blological organisms. ‘These factors may be Inter-active with each other and all factors need addrassing to ensure ‘a good quality system. Local authorities may have their own particular requirements. f Soli Since evaporative coolers act as ‘ait scrubbers’ a large amount of debris is collected to accumulate along with the solids Jhardnoss) already present in the water. As the water evaporates, all this solid matter is left and the residual circulating water becomes gradually more loaded with solids, {if the concentration of the dissolved solids is allowed to become too high, then the solubility of the impurities will be exceeded and scale/sludge will be deposited. It must be remembered that every 100 ppm hardness in the make-up water will produce 0.1 kg of sludge or scale on the evaporation of 1m? of water. Itis therefore essential to control this level of deposition, which is generally achieved by the use of chemicals and by bleeding-off a certain amount of the circulating water, blow downl. ‘A reduction in the blow down rate of up to 70%, and in chemical costs of 50%, can be achieved in hard water areas by use of a water softener, j.e., by passing the make-up through a base exchange softener. Such a procedure can show a payback period of less than two years over ‘a ‘chemicals only’ scheme, Each application should therefore be examinad to decide whether a base exchange softener can be justified on operating costs. The design of the pipework carrying the softened water before injection into tha system should allow for the corrosion potential of softened water. ‘Concentration Factor Concentration Factor is the ratio of the system TDS (Total Dissolved Solids) to the make-up water TOS, Thus a system TDS of 1500 ppm made up with water of 300 ppm has a Concentration Factor of 5. If soft water is used, a Concentration Factor of around 6 could be allowed, but hard water would reduce this to about 2.5. .d-off or purge flow rate can be calculated from:- HI x where:- Q_= Bleed-off flow ( litres/s ) Qo -———_ E = Evaporation rate { litras/s } H2 - HI H1 = Supply water hardness ( ppm) ‘System water hardness (ppm) © Haden Young Ltd.TM 4.3.31. page 2 COOLING WATER TREATMENT Jan 94 rev3 4, 5. Blow Down Methods Various methods for control of blow down can be adopted: 1. Volumetric contral, which relies on a water meter measuring the mak signalling the purge valve to open and discharge an amount proportional to the make-up volume. The moter can also control the proportional dosing of chemicals. The method is simple and sufficiently accurate in practice, though not as accurate es the conductivity conteol method. 2. Conductivity control, which consists of a conductivity call placed in the circulatory system; this coll continuously measuras the conductivity (an indicator of TDS) of tha system water. ‘When it rises above a certain level, a signal initiates the opening of the solenoid operated purge valve, which remains open until the conductivity reaches an acceptable tovel. For the mathod to remain accurate, the conductivity coll must be kept clean at all times and this is the drawback to the method in practi ing ion Prevent Depending on the alkalinity or acidity (pH! of the circulating water, there will be a tendency for scaling of corrosion to take place. Water treatment chemicals are available, las a singlo “cocktail"l, to simultaneously control both possibilities. These will generally be formulated to maintain a high solubility of scale forming salts. (this also helps sludge control). A corrosion inhibitor is also included, Micro-bioloniesl Oraaniame?**** Since the water in evaporative cooling circuits contains solid matter, i.0., it is full of chemicals, aerated and relatively warm, a good environment is created for a number of micro- biological organisms to breed in. These organisms can.praduce slime and inhibit heat transfer or water fiow. More significantly, bacteria which can cause illness, 0.9., Legionaires Disease, can breed. For prevention of the above, it is necessary to add chemicals (biocides) which will prevent their growth and to design and install the system so that cooling towers can be cleaned easily Recommendations should be sought from a water-treatment specialist for types and number of biocides raquired. It will bo normal for two types to be supplied, i.e., an organic biocide and an oxidising biocide, The organic biocide will normally be used in rotation with a different organic biocide to prevent the building-up of immunity in the micro-biological community. ‘An oxidising bioc! ‘chiorine, will also be added to the water to maintain a minimum concentration. Bromine is also a potential, albeit less well racognisad, oxidising biocide. The pH level of the water is important for these biocides since their effect is only sustained at rolativaly high pH levels. Bromine appears to be slightly better in this respect. Water Company permission is necessary for the disposal of the residues through the drainage system into the sewers. Latest practice will be influenced by various advisory and statutory documents. The impact of each document should be examined and if the buildings or immediate area includes hospitals or similar establishments, then special precautions may be necessary; always consider air cooling as ‘opposad to evaporative. © Haden Young LtdcA mW TM 4.3.31 page 3 COOLING WATER TREATMENT Jan 94 rev3 Practical Analications ‘The methods of administering the treatment and ensuring a good distribution Is as important ‘as deciding the treatmant chomicals, Thought must be given as early as possible and incorporated fon design drawings. Maintenance Is an essential part of a successful water treatment regime. Chemical Dosing Chemical dosing can be by manual or automatic means. Manual dosing Is only satisfactory for small systems with light constant load. Automatic dosing can be achieved by a dosing pump running continuously, or for pre-set periads each day. This does not allow for load changes, and tha more accurate mathod Is to use a water meter which measures the make-up volume and signals the pump to inject chemical in volumetric proportion, Another advantage of this method is that the meter can also be used to control the dump control valve. ‘An initial appraisal should be made to sae whethor or not a base exchange softening plant ‘can be justified, The chemical dosing equipment would then be modified to suit the softened water condition. It is important that the chemicals and especially the biocides, are allowed to reach all parts of the system, i.e., no dead flow ar Listed below are the points which should be considered:- 1. Stand-by pumps must be run on a regular basis to give flow through associated pipe-work - this can be part of the automatic control system. 2. Balance pipes on cooling towers should have a small continuous fiow, i.e., do not balance tower flow in and out precisely, to encourage flow from one tower to another in the balance pipe. 3. Levels of chemicals must be checked manually even where dosing is automatic. Sampling poirfts should be provided at appropriate points, say, cooling tower ponds, within long pipe- work runs and after heat exchange surfaces. 4, Provide drain points at tha foot of risers for removal of sludge or other deposits. However, avoid too many dirt pockets since these could provide a breading area for bacteri Pipswork, especially balanca pipes, should have disconnect joints, (e.9. Victaulicl, and drains to facilitate inspection and cleaning. 6. BS 1387 mild steel pipe-work is normally acceptable but it must be ensured that the design of the chemical treatment is compatible with this mat 6. Ensure that any blow down (over-flow or drain), does not discharge into a drain where it can enter (by gravity) any other plant. 7. Use high efficiency eliminators on cooling towers to avoid the spread of droplets and to conserve water treatment chemicals. © Haden Young Ltd1M 4.3.31. pages COOLING WATER TREATMENT Jan 94 rav3 7.2 Maintenance For a water treatment system to be effective, simple and easy maintenance should be incorporated. Many outbreaks of Legionalres disease are caused by lack of maintenance which is ‘encouraged by poor facilities to do the maintenanct Items which should be considered under this heading are:- 1. Ensure easy access into the tower and consider a viewing port in the side of the tower with internal tight. 2. Dopatprovide a high pressure spray point close to the tower, Cleaning with a high pressure spray may create bacteria carrying droplats whilst the cleaning is being carried out. 3. Recommend that water treatment and general maintenance of cooling towers is sub- contracted to specialist sub-contractors, but, at the same time, wo should recommend that a specialist, Independant of this sub-contractor is used for monitoring of the biological conditions of tha system, The tower may require registering with the local authority so that the condition of tower and water treatmant can be regularly inspected. 4, Storage areas must be set aside for chemical containers with restricted access. A normal locked plant area sould be sufficient. A reasonable access route for moving chemicals should also be available since these can come in large drums/sacks. 5. COSHH hazard warning sheets must be supplied by the water treatment specialist and consideration must be given to the noad for emergency spillage treatment, 9.9., shower. References: CIBSE - Technical Memorandum 13 : 1991 DoH - Health Service Management : The Control of Legionel 1988 HSE - Guidance Note : The Control of Legionsllosis, Including Legions 11991 HSC - Approved Code of Practice : The Prevention or Control of Legionellosis (Including Logionsiras Disease) Local Authority Guidel Haden Young Safety Procedures Directive for Control of Lagionellae in Buitding Services Instatations.. BO Re oo © Haden Young LidRelated Topics TM 4.332 — Water treatment of chilled water systems Post-it Note ‘The main TM section and the related topics give basic information only and are not necessarily up to date, so refer also to: CIBSE Guide B: Section 87-7, 11 & 12ic a. Zz ial Qa t x 2. at 2.2 2.2.1 2.2.2 2.2.3 TM 5.1.32 page 1 MTHW AND HTHW SYSTEMS Sep 83 rev 2 MTHW AND HTAW SYSTEI Scope The general requirements of MTHW (99 - 120°C flow temperature) and HTHW (above 120 °C flow) systems are described with notes on the factors to be considered when selecting from LTHW, MTHW, HTHW and Steam. Flow temperatures and temperature drops are suggested. Requirements of system layout and components are given, frequently by cross-reference to other TM papers. Choice of MTHW and HTHW Process Systems Where heat is required for process work, MTHW and HTHW systems offer the following advantages over steam : 1, ‘They allow modulating control. 2. Corrosion control is easier. 3, Losses associated with condensate return are avoided. 4. Boller pressure derating is unlikely. Conversely, a steam system is more able to absorb sudden fluctuations in load. Heating Systems ‘The advantages of smaller pipe sizes and heat emitters used in MTHW & HTHW systems compared to those used in LTHW must be balanced against the following disadvantages : 1, Higher quality materials and workmanship to withstand the higher pressures. 2. Additional space and cost of the pressurization equipment (unless natural head is available) and water treatment plant. 3. Gontrol more critical. 4, Extra maintenance skills required. For MTHW, a system distributing more than 1.5MW is needed before there is any saving on capital cost. Very little further capital saving can be made with an HTHW system which is normally only used to meet process requirements or in district heating schemes. The ability of staff to undertake the extra maintenance of an MTHW/HTHW system should be considered (eg examining valves for gland leakage ; maintaining additional plant ; understanding and operating the more complicated safety and emergency control procedures). It may be in the client's best interests to install a slightly more expensive LTHW system than a system which he will not be able to maintain satisfactorily.TM 5,1. 92 page 2 MTUW AND HTHW SYSTEMS Sop B3 rev 2 Design low Temperature ‘The flow temperature chosen should be the maximum compatible with the pressure characteristics of the equipment and system. In process systems, the flow temperature should be chosen to suit the process requirement. For MTHW systems a flow temperature of 120°C will often be suitable where pressurization equipment is used; if static head pressurization is used the flow temperature must be related to the head available. For HTHW heating systems, it is not normally economical to excced a flow temperature of 150°C. When selecting a design flow temperature, consideration must be given to any boost requirement, as the margins normally allowed for hoost conditions do not exist. When a flow temperature has been selected the pressure implications should be examined (see TM 5.1. 31). It may be advantageous where cost savings would accrue,to alter the temperature slightly to take account of the pressure ranges of commercially available equipment. oid NaavH ® | ‘low temperature stability is discussed in TM 8. 1.12 Design ‘Temperature Drop ‘The temperature drop which can be allowed increases as the flow temperature increases. A drop of 30-35°C is suitable for MTHW and 45°C for HTHW. Larger differences will aggravate problems of control and thermal shock, while smaller differences result in larger pipe sizes which may nullify the case for using MTHW/HTHW. In process work, however, smaller temperature differences may be dictated by the process requirement.sdund Buyyesedo - yyun duind Suqwuna ~£qjuayyunzeqy yp Tassan aanssard epee be 3 -&isnonupuoo fq uopjezyinsserg ¢ “Sta uojysno-ua8os}tN Sq uoyeztansserg 2°81 kq woyeztanssaig 1 “Biz 2a (U0 '6 * WL VOL) (IE "WL UH0R) an seen a wane Ez # + Ba aes nee ak ase TT 628 eens 2 2E8 oo aid N3avH ©TM 5 MTHW AND HTHW SYSTEMS Sep 83 rev 2 5 5 6 5.7 1.32 page 4 Pressurization Equipment Pressurization by head tank should be the first choice where possible (ig. 1) Where the available head is inadequate, packaged units are normally used employing either a nitrogen-cushion pressure vessel with intermittently operating head pump (Fig. 2) or continuously running pumps (Fig. 3). Steam pressurization may also be used but is best avoided. Continuously running pump units are cheaper infirst cost. They have the disadvantage of allowing system pressure to fall rapidly if there is equipment-or power failure. They are most suited to systems where frequent expansion and contraction cycles occur Where short-term variations in system temperature occur (eg temperature swing caused by on/off boiler firing to meet a small load) a buffer vessel (see Fig 1) should be incorporated between the system connection and pump/relie? vaive, sized to accommodate the expansion water produced by the short-term variations with a substantial margin. If a julfer vessel is not provided, hot water will pass into the spill tank causing difficulties with the relief vaive and pumps. Nitrogen cushion pressure vessel units will maintain system pressure for a longer period under failure conditions. The pumps only run intermittently, and therefore require less maintenance and are less likely to suffer failure. They should be used where systems are stable in operation with gradual changes in loads ‘The circuit arrangement shown in Fig. 2 ensures that feed and expansion water passes through the pressure vessel; this periodically heats its contents to prevent the growth of sulphate-reducing bacteria. Oxygen pickup at the water surface of the spill tank should be prevented by the use of Aliplas spheres, or with a nitrogen bell (as shown in the diagram) An enquiry for pressurization equipment should give the following: Flow temperature Return temperature Water capacity of the system Boiler water capacity Maximum likely rate of heating/cooling’ Flexible diaphragm units should not be used in their standard form for MLIIW/HTHW systems as they are not siipplied with adequate equipment; see TM 5.1.15. ‘wis ta oav!loularty important 1n the oase #f precess systens where recy rapid ehanges Th ayaten tenperatire may oscur. The maxinun soeling rate ts usually taken ss the Liteat nf stopping the largest vofler in the systen, but could be caused by svitehing a process = ur heating load larzer than the largest voller 7 Contraction rate (14tre/e) = Load Suitehed(iN) x 260x10 Asnure 3d NaavH @@® HADEN ple 10, TM 5.1.32 page 5 MTHW AND HTHW SYSTEMS Sep 83 rev 2 Water Treatment It is essential to provide appropriate water treatment (see TM 4,3. 11 and 4. 8, 12) if difficulties with the plant are to be avoided System Layout Care must be taken to keep the levels of the highest and lowest pipes within the design values used in calculating the pressure requirements of the system. See TM 5. 1, 31. Heat emitters and pipework must be selected to be suitable for a working pressure which is the pressure resulting from normal modes of operation. Test pressures must be not less than any pressure it is possible to impose on the system by abnormal operation (eg pumps operating with closed valves). Where there is a choice of location, control valves, orifice plates etc. should be located at the pump delivery to drop the pressure before it is transmitted to the remainder of the system. Connections to equipment should be arranged so that gravity circulation assists pump circulation; this will avoid dead spots due to internal circulation In tall buildings, adjustment to the pump pressure should be made for gravity head either assisting or retarding circulation. ‘To enable commissioning to be carried out, the provisions set out in 'TM 9,6 11 must be included. Pipework Expansion Particular care must be taken with pipe layouts to cater for expansion and provide adequate anchoring; see TM 9.9.11 and 9 9. 21 Pipe Sizing For pipe sizing procedure, see TM 9.2.11 For data for pipe sizes larger than 300 mm: for temperatures up to 120°C see TM 9.2. 41 for temperatures above 120°C refer to HCE System Cleanliness System cleanliness is important in MTHW and HTHW systems; see TM 9,6. 13 for precautions to be taken.IM 5.1.32, page 6 MTHW AND UTHW SYSTEMS Sep 83 rev 2 uw Material Specifications Appropriate materials and their use in MTHW/HTHW systems are described in TM as follows: Pipework and jointing: MTHW TM 9.10.14 - : HTHW 9,10. 12 Valves IL 2, 21-24 Insulation 18.1.11/ Pumps 10. 1. 11 * Expansion bellows 9.3.11 Anchors 9.9.21 ¢ Coils 6.5.12 * ‘Thermometers, pressure gauges and cocks 15.2, 11> ‘Thermometer test points 9.6.12 x Calorifiers 7.1.41-43 ¢ Unit heaters 6.2.41 * 11.2 For standard arrangements of pipe connections, instrument connections ete, see Standard Drawings Manual. od Naqvn @Related Topics Refer to the TM sections noted In 5.1.32 Post-it Note ‘The main TM section and the related topics give basic information only and are not necessarily up to date, so refer also to: Sections 81 - 12 to 16 CIBSE Guidea a oa ©k 1 2 TM 9.8.11 STEEL PIPEWORK EXPANSION Jan 81 DESIGN FOR EXPANSION OF STEEL PIPELINES Introduction Linear expansion of low carbon steel Dimensions of steel pipe Flexibility tables for (a) dimensions (b) anchor load due to bending for 4.1 a single bend 4.2 a double bend or offset 4.3 a U-shaped loop 4.4 a branch at right angles to an expanding main 4.5 a vertical riser Additional anchor loads from friction over guides and supports Axial bellows Hinged bellows or ball joints Support spacing Guide spacing page 1 rey 1 Page... 2 3 4 5 6-9 10 - 16 17 - 22 23-24 25 ~ 27 28 20 - 34 35 - 40 40 40-41TM 9.3.11 page 2 STEEL PIPEWORK EXPANSION Aug 87 rev 2 ey wed 1, Introduction : Lat ‘The stress in a pipe due to bending depends on the OD, The data in this paper applies to piping whose OD is to ISO 64) corresponding to.the ODs (but not thicknesses) of BS1387, BS3601, and API 5L tube, as well as the standards of other European countries, ‘The anchor load calculation (from the tabulated factors given in ‘Table 4, 1,2 et al) uses the Moment of Inertia of the pipe's cross-section ; some values, corresponding to Company standards, are given in Table 3, but values of I for other wall thicknesses must be calculated. 1.2 All sections are to be made up with welded joints, No screwed joints are allowed in expansion members and, as far as possible, pairs of flanges (where necessary for erection), valves, traps, strainers and other such equipment should not be located between piping anchors in any piping designed to absorb expansion by bending. They should preferably be located in piping where the loads are purely axial, as, for example, between guides = — or between an anchor and a guide. When they must be located in members x subjected to bending, a location in the longer of two adjacent lengths of pipe zB should be chosen, g 1,3 In preparing the Tables in 4, a maximum stress of 51.7 N/mm? (7500 a Ib/in’) at any point in the piping configuration has been used. This Qo apparently conservative value of the stress has been chosen to give an $ adequate margin below the normal maximum value of 96,5 N/mm? for oO low-carbon steel piping, to allow for any additional stresses caused by 5 the internal pressure (which is assumed not to exceed 2,07 N/mm?- a 8 (300 1b/in2))or the deflection of the pipe due to bending between its supports (which are spaced at intervals not greater than the values given in TM 9.9.11). It is further assumed that the imposed dead loads are limited to pipe contents and lagging, 14 Stress intensification at bends and tees is included in the 51,7 N/mm?. B9806 ; 1986 uses larger values for stress intensification than those used in caloulating the data in this paper but compares the results with a proof stress which is greater than the working stress. ‘The overall dimensions required using either this paper or BS806; 1986 are similar. BS806:1986 therefore should not be used for stress calculations unless this is a requirement of a consultant's specification and he cannot be persuaded that the ‘TM method is satisfactory. 1.8 ‘The tables give the dimensional proportions,’ and anchor loads due to bending, of the named configurations stressed to the above limit when raised in temperature from the assumed base value of 0°C to the working temperature, without the application of cold draw, The modification resulting from the application of cold draw is set out, and an example calculation given. 1.6 Sideways restraints (ie restraints in the plane of the paper for the piping elements as drawn in the Tables in para 4) are not permissible between anchors, or between guides where guides are shown, The pipes must be properly supported at the appropriate intervals (see TM 9, 9,11) either on hangers with drop rod lengths not leas than those shown in TM 9,9, 18 or on sliding supports which permit axial and sideways movement,© HADEN YOUNG LTD 17 TM 9.3.11 page 3 STEEL PIPEWORK EXPANSION io rm Jan 81 rev 1 Anchor loads comprise the sum of the end forces due to pipe bending (obtained from the Tables in para 4), the forces due to friction in sliding over supports and through guides (para 5), and, for bellows joints, the forces due to internal pressure extending the bellows (paras 6 & 7). ‘The design of anchors to resist these loads, and their fixings to the structure, is set out in TM 9,9, 21 and TM 9.9.23. Linear expansion of low-carbon steel ‘Temperature Expansion ¢ per unit length °C oF mm/m TABLE 2.1TM 9, 3,11 page 4 STEEL PIPEWORK EXPANSION Jan 81 rev 1 vebed 3 Dimensions of steel pipe ‘The outside diameters of pipe up to and including size 125 correspond to BS 1387, European standards such as DIN 2440, DIN 2458 ote. and the ISO 65. For 150 and above, the ODs correspond to BS3601 and:ISO 134) Note that, for calculation of anchor loads for pipe wall thicknesses different from those tabulated, the Moment of Inertia of the cross section must be calculated from the formula I= @-d) where D is the outside diameter and d is the inside diameter Nominal Wall Moment | ‘@ | Wall Moment size |thickness| of Inertia | § jthickness| of Inertia mm mm mm* a | mm mum 2, 65 Tx 10° 1 25, 8 x 10° 2. 65 15 x 10% 3, 25 17 x 107 3.25 37x 108 4,05 43 x 10° 3,25 78 x 108 4,05 91 x 1065 $8.25 118 x 107 4, 05 140 x 10% 3. 65 262x 10% 4,50 309 x 10° 3.65 | 544% 10? 4.50 | 648x 10° 4, 05 760x109 |. | 4,85 | 1.13x 10° ail 5.40 | 2.73x 10° 4,50 | 2,33x 10° Heating (TM 9.10.11, 9.10.14)! ‘Company Specifications forl/THW and MTHW Company Specification for HTHW Heating 4.85 | 467x108} 5S] 5.40 _| 5,13 10% 5.6 9.48x 10°] Bos] 5.6 9,48 x 10 5.6 21.4% 108 z 9.6 © /21,4 x 10° 635 | a7.ox to] R-| 7.1 |52.5 x 10° Wal 88,6 x 10 8.0 |99,0 x 10% 10,0 [162 x 108 10,0 |162 x 10% 0 4245 x 10% 10,0] 245 x 10 606 x 10° 12,7 | 608 x 10° " pape to 281387 and 383602 TABLE 3 avn G INADA ani (@© HADEN YOUNG LTD TM 9.3.11 page 5 EP? STEEL PIPEWORK EXPANSION ase Lak Jan 81 revi Flexibility Tables ‘The Tables in this section give the proportions of various shapes of piping which will have sufficient flexibility to yield to the expansion when raised in temperature from the assured base ter:perature of 0°C to the working temperature without the stress at any point in the piping exceeding 51. 7 N/mm?(7500 lb/in’), The value assumed for Young's Modulus E is 200000 N/mm?(29 x 10®lb/in*). Opposite the dimensional Table (eg Table 4.1.1) is a corresponding Table (eg Table 4.1, 2) from which the anchor thrust due to expansion can be calculated. Consistent units must be used; Tor example Moment of Inertia 1 mnt Length Lomm Modulus of Elasticity E N/mm? (which is numerically the same as MN/m?) will give a ‘Thrust F in newtons. Tlie remaining components making up the total anchor thrust are calculated from para 5 (p28). ‘The modified calculation, appropriate when cold draw is applied, follows the second Table for each piping configuration, For econorry in sizing expansion bends, offsets and loops, a cold draw of up to 50% of the total expansion may be given, It can only be used when the ends of the pipe section are very firmly anchored, If the pipe is suspended on hangers and, as is often the case with suspended pipework, the effectiveness of the anchorage is dubious, it is wrong to suppose that cold draw can be applied- or, if applied, will be retained, In all such cases the configuration should be designed for the full expansion and no cold draw applied. Cold draw is not appropriate for working temperatures below 80°C, Only values shown on the Tables should be used; other values are not permissible as the configuration is either not sufficiently flexible or is liable to buckling.TM 9.3.11 page 6 STEEL PIPEWORK EXPANSION Nov 72 4.1 Expansion of a steel pipe single bend i Allowable dimensions L hand D allin Panel h. consistent units re 264 _[ 320 | 300 140 | 160 | 180 TO/ Ty SRY.) rT Tee 33.3] 26.6] 20.77 31.4 1.2] 6.8 | 10.51 14.0] 18.0] 22.0 29.8] 34.0 37.91 40.1 ( 4.4} 8.6 | 13.2 | 17.6] 22.7] 27.7 37.5| 42.8] 47.8; 50.6 1.6} 10.5 | 16.2 | 21.6] 27.8] 33.9 45.9] 52.4) 58.5{ 62.0 4.8} 12.4 {19.4 | 25.8] 33.3! 40.6 55.0] 62,8 70.1; 74.2 0} 16-1 [23-2 | 31.0] 40.0] 48.7 66.0] 768} 84.1, 89.0 2.2) 17.7 [27.4 | 36.4] 47.1] 57.3 77.6| 88.6 98.9] 105 2.4) 20.7 | 31.9 42.5] 54.9! 66.9 90.6 }403 | 115 | 122 2.6! 23,6 |36.7 48.9] 63.2 77.0 104 9 }133 | 141 2.8| 27.1 | 42.0, 55.8] 72.1 87.9 ui9_f136_|152_ | 161 3.0) 30.6 [47.7 63.5] 82.0 95-8 3p Ted i72 | 18: 3.2! 34.5] 53.4 | 71.0} 01.8 112 163 | 193 | 204 3.4| 38.2 | 59.1 78.6{102 , 124 168 [171 {213 | 226 3.6| 42.4 {65.5 e7.1 {103 137 186 | 212 | 237 | 250 3.8| 47.1 | 72.5 96.5125 | 152 206 {235 | 262 | 277 4.0] 51.5] 79.7 106 [187 167 226 [258 | 208 | 508 4.2| 86.2] 86.9 :116 149 247; 281 | 314 | 332 4.4| 61.1 | 94.4 126 i 268 | 306 | 341 | 361 4.6) 66.4 [103 137 215 291 | 332 | 371 | 393 4.8) 71.9 fit i148 233 315 360 | 401 | 425 5.0] 77.8 [120 160 25: 34a [390 [4 461 5.2 | 84.0 130 (173 272 368 420 | 469 | 497 5.4} 90.2 139 :185 201 395 ; 450 | 503 | 532 5.6) 96.2 a9 66 312 422 | 481-| 537 | 569 5.8|103 [15912 333 450, 514 | 574 | 607 6.0 filo i7g~ 1226 1355 4ei_ 649 | 612 | 648 6.2 117 fis) j240 377 sil. : 583 | 651 | 689 6.4|124 |192~ [255 | s29 | 410 544 620 | 692 | 733 ' 6.6 |132 203 [271 | 350 | 426 sv? | 659 | 735 | 778 6.8 {139 fats |2e7_ | 370_| 451 6il_| 697 | 778 | 9824 7.0 |ia7T pear [302 [391 | 476 645756 | 622 | 870 7.2|155 i240 [319 |412 | 502 679/775 | 865 | 916 7.4 |163 252 [335 [433 | 628 714 | 815 | 910 | 963 7.6 [171 [264 352 [455 | 554 7150 | 856 1.8 370 789 6.0 390 31 TABLE 4.1.1 @17 DNNOL NTM 9.3.11 page 7 STEEL PIPEWORK EXPANSION Nov 72 4.1, Expansion of a steel pipe single bend Contd. Anchor loads due to expansion hk loo ‘Thrust F = K (7! yy) where F = thrust at anchor h E = modulus of elasticity 1 = moment of inertia of A cross section L = length (all in consistent units) PIPE ThMPERATURE L [ora TTS] 212 | 264,320] 306] 300] 410 h Cae 6o{ 80} 1001 120 | 140,160 [180] 200 | 210 5 ¥ TO; Ty 12.9 15.9) 20.6] 25.1) 20.6) 33.9 a2) 45.8 1.2] 9.7| 15.1) 20.0] 25.9] 31.5] 37.2] 42.7 54.4) 57.6 1.4 | 12.1) 18.8] 25.0] 32.3/ 39.3) 46.4] 53.2 67.8, 71.8 1.6 | 16.6) 24.1] 92.1] 42.0| 50.6| 59.7) 68.5 87.2} 92.3 1.8 | 20.5] 31.7] 42.11 54.4] 66.3) 78.2) 89-.103 | 114 | 121 2,0 | 25.9} 40.0} 63.2] 68.8) 83.8} 98.9) 113 Yao) 145 | 153 2.2 | 32.3| 50,0] 66.5! 85.9] 105 | 124 | 142 |“1e2 | 181 | 191 2.4} 39.7/ 61.3] 81.6) 105 | 128 | 152 | 174 | i99 | 222 | 235 2.6 | 48.1) 74.3] 99.0] 128 | 156 | 184 ag 241 | 269 | 284 2.8 | 58.2| 90.0] 120 | 155 | 188 | 222 2o1_| 325 | 344 3.0 | 69.6} 108 | ids | igs |"225 @) 305 | 349389 | 412 3.2] g1.1] 125 | 167 | 215 | 262 | 310/355 | 406 | 453 | 479 95.7) 148 197 254 310 366 420 479 535 566 uo | iso | 255 | 201 | ase |wus | 400 | saa | sit | sa? 126 195 259 335 408 481 552 630 704 745 145 224 299 386 470 55! 637 727 Bil 858 164 253 336 435 529 625 17 818 913 967 186 288 383 495 14 712 817 933 1040 1100 209 324 431 556 800 918 1050 1170 1240 235 364 484 626 762 900 1030 1180 1320 1390 262 404 538 6 847 1000 1150 1310 1460 1550 284 440 585 7 921 1090 1250 | 1420 1590 1680 321 496 660 853 1040 1230 1410 1610 1790 1900 365 | 549 | 731 oes 1150 [1360 1560 |1780 |1990 |2100 606_| 80g |toso |1270 |1500_|1720 |1960_| 2190 | 2320 430 | 665 | 8a j[1140 [1300 [1640 [1890 [2150 | 2400 [2540 aca | 723 1240 }1510 |1790 |2050 |2340 | 2610 |2770 509. | 787 1350 |1650 |1940 | 2230 |2550 | 2840 | so10 556 859 1480 1800 | 2120 2440 | 2780 3100 3280 602 930 | 1240 1600 1950 [2300 2640 | 3010 3360 [3560 654 10) 1340 1740 [2120 [2500 2870 3270 3650 [3860 695 108 1430 1850 | 2250 2660 3050 3480 3880 | 4110 758 1170 1560 |2020 | 2460 2900 | 3330 | 3800 |4240 1/4480 818 1260 1680 [2170 |2650 |3130 | 3590 | 4100 | 4570 |4840 878 1360 (1810 {2330 [2840 | 3360 3850 | 4400 | 4910 5190 944 1460 1940 [2510 3060 J 3610 [4140 14720 5270 5580 Jo]O ODM OlO DANE aD wolaaRN|IDam [Jas Adooaodeuacde sree oo TABLE 4.1.2TM 9.3.11 STEEL PIPEWORK EXPANSION Nov 72 4.1.3 page 8 Cold draw with single pipe bend ‘When 50% cold draw is to be applied, select the size of bend from Table 4.1.1, not for the design working temperature but for a fictitious working temperature selected from Table 4.1.3. Design Fictitious: Expansion coefficient working design temp € x 108 temp, (yp) (e.g. mm/m) For calculating Cold Draw aw 2 @) we Fr °C 176 80 | 104 40 0.458 194 90 | 122 50 0.580 212 100 |140 60 0.708 230 110 |140 60 0.708 zag | 120 |168 | 70 0.820 266 130 | 158 70 0,820 284 140 |176 80 0.942 302 150 | 176 80 0,942 320 160 [194 90 1.070 338 170 | 194 90 1.070 356 180 | 212 100 1.217 374 190 | 212 100 1.217 392 200 | 212 100 1.217 410 210 | 230 110 1.350 ‘This Table also gives the amount of cold draw to be applied at an installation temperature of 0 °C; ambient temperature prevailing at the time of installation Ta by the formula TABLE 4.1.2 this has to be corrected for the where C.p, is the amount of cold draw to be applied is the amount of cold draw at 0°C = &x L; € taken from Cc. ‘Table 4.1.3, col 3 Y L length in consistent units TT, 18 the fictitious temperature from Table 4.1.3, col 2. Contd;4.1.3 TM 9.3.11 page STEEL PIPEWORK EXPANSION Nov 72 Cold draw with single pipe bend Contd. EXAMPLE: Given a single bend where L= 160D at a working temperature A 1D. o/o of 160°C. Required to find (a) values for h without and with A 50% cold draw (p) amount of cold draw when ins- talled at 20 °C. (a) Without cold draw, from Table 4.1.1 - for pipe temperature 160 °C L and [> = 160 is 3.3 approx. With cold draw; Fictitious temp T,, from Table 4.1.3, is 90 °C. L L ‘Then from Table 4.1.1, 7 for 90°C and B = 160 is 4.6 approx (b) Amount of cold draw at 0°C from Table 4.1.3, col. 3 1,070 Ree x 160D = 171.2 ial “ror P Cn =C. @ 20). M2 70)= 183.2 30> 0 To P( 90 To P On working drawings, the amount of cold draw to be applied must be related to the actual ambient temperature at the time of application (T,). ‘This is best done (1) By noting against each position the value of C, . ee (2) By drawing a graph of Fa against T,, to give the factor by i which the values of C, “must be multiplied. Thus for the example above the graph would be; Paotor Fig. 1 “100” 368950 Anbient temp “eTM 9.3.11 page 10 STEEL PIPEWORK EXPANSION 7 Nov 72 4.2 Expansion of a steel pipe double bend Allowable dimensions for ¢ = 1.0 Lh D a b all in consistent units 212 | 248 264 356 [300 ico | i120 [140 60 | 200 alae moo ae Basses ho al to on ie SSaBs Sale 2 8 ° 1 q 3.9] 96.3 89.3 | 103 93.4 | 107 98.1} 113 Tot; tid 108 | 124 114 | 130 118 136 124 | 142 129; 148 Se LS ANTS 96. 139 | 159 143 | 165 149 | att ea { 17 159 | 183 162 | 186 169 | 194 175__| 200 180 | 207 1e5__| 212 190 | 218‘TM 9.3.11 page 11 STEEL PIPEWORK EXPANSION Nov 72 Expansion of a steel pipe double bend Contd. Anchor loads due to expansion. § = 1.0 ‘Thrust F = K (_,E!__) where F = thrust at anchor {pero E = modulus of elasticity I = moment of inertla of ae cross section I= length (All in consistent units) PIPE TEMPERATURE oF 7 b 7 64 350] 308] 410] 4EC] 60 so | 100) 120 [140 [iso [iso 200] 210) ae wr o@aa Noval yomalavnowmakwoaalanoaal sft 2 a 2 3. 3. 3 5 3. wy a TABLE 4.2.2TM 9.3.11 page 12 STEEL PIPEWORK EXPANSION ~ Nov 72 4.2 Expansion of a steel pipe double bend Contd. Allowable dimensions for # = 1.5 Lh D a b allinconsistent units * A PIPE TEMPERATURE OT 110] 176 i2_[ 240 [ 28¢ [320] 380] 300] 410 iM go | 100 Jiao 140 igo] 200 jf 210 MINIMUM VALUE IC 160, 0.6 | 15-5 20.8) 27.7 | 35.8] 43,6 0.8 | 11.2 | 17.3 | 23.0] 29.7] 36.2 10.3 | 15.9 | 21.1.] 27.3] 33.2 +2} 10.3 | 15.9 | 21.1] 27.3] 33.2 10.3 [15.9 | 21.1 | 27.3 | 33.2 10.4 |i6.1 | 21.5 | 27.7 | 33.8 11.2 117.3 | 23.0] 29.7] 36.2 12.0 | 18.6 | 24.8} 32.0] 39,0 12.9 | 20.0 | 26.6] 34.3] 41.8 14.2 | 21.9 | 29.1 | 37.6 | 45.8 15.1 | 23.3 | 31.0] 40.0] 48.8 16.3 | 25.2 | 33.5] 43.3] 52.8 17.4 | 26.8 | 35.7] 46.1 | 56.2 18.6 | 28.7 | 38.2 | 49.4 | 60.2 19.6 | 30.7 | 40.8 | 52.7 | 64.2' 3 3 21.1 32.6 | 43.3 56. 22.3 34.5 | 45.9 59. 23.5 | 36.4 | 48.4 62.6 24.8 | 38.3 | 51.0 | 6: 26.2 | 40.5 | 53.9 | 6 27.4) 42.4 | 36.4 (hve. 28.7 | 44.3 sore 29.9 | 46.2 | 61.5} 79.5 31.3 | 48.4 ws 83.2 32.6 | 50.3 | 6?.0 | 86.5 34.0 TS: 69.9 | 90.8 35.2 | 54SeJ} 72.4] 93.6 36.6 | 56,6 | 75.4 | 97.4 38.1 | 58.8 | 78.3 | 101.1 39.5 | 61.0 | 81.2 | 104.9 40.7 [62.9 | 83.7 | 108.2 42.1 | 65.1 | 86.7 | 112.0 43.4 | 67.0 | 89.2 | 115.2 44.8 | 69.2 | 92.1 | 119.0 46.0 | 71.2 | 94.7 | 122.3 47.4 [73.3 | 97-6 | 106.1 100 103 oS eS Pe CORD OMAN S® dR Noe TIAL O@ OT SSS OSS Oo ee ee as7__ | 272 lo}@ a) Om alk Oo olay STITT TABLE 4.2.30 .—‘TM 9.3.11 page13 STEE] PIPEWORK EXPANSION Nov 72 4,2 Expansion of a steel pipe double bend Contd. Anchor loads due to expansion § = 1.5 Dal thrust at anchor modulus of elasticity moment of inertia of cross section L= length (All in consistent units) PIPE THMP ERATURE Thrust F = K oan where F E I a L T T iT 46 | 26 o h [ancy 60 601100 [i120 [i40 [60 | 60 | 200 | 210. VALUES OF K iT 7.5] 36.0] 47.5) o7-6] 68-i[ 78. Bo.17 99.6) 105 16.9] 26.1| 34.8} 45.0| 54.6] 64.6) 74.2] 84.5) 04,5) 100 17-2) 26.¢| 35.3] 45.8| 55.5) 65.6) 75.4 96.0} 102 18.7] 28.9] 38.4| 49.8} 60.4/ 71.4) 62.0] 9 10a f int 20.6| 31.9] 42.4| 54.9] 66.6) 78.8| 90.5] 1037) 115 | 122 Tso] 38.6} 47.4] 1-4] 74.4) 66.0[ for | 115 [120 [136 25.9| 40.1| 53.3} 69.1] 83-6) 99.1) 114 E)I30 | 145 | 153 29.6] 45.8| 60.9] 78.9) 95.8) 113 | 130 \Wi4e | 166 | 175 33,8] 52.3| 69.5] 90.0] 109 | 129 | 148 | 169 | 189 | 200 3e.7| 59.9 | 79.7] 103 | 126 | 148 A 194_| 217 | 229 44-21 68.3] 90.6] 118) 143 | 169 | Wa | 22i [247 | 261 50.4] 77.9|104 | 134 | 163 | 193) 221 | 252 | 262 | 298 56.3| 87.1] 116 | 160 | 182 | 21 247 | 282 | 316 | 333 62.7] 97.0|129 | 167 | 203 | 240 | 275 | 314 j 361 | 371 70.6|109 [145 | 188 | 228 |.27, 310_| 363 | 394_| 417 2.0] 128 ivi | 221 | 268 Str 3a | 414 | 40s | 401 a7.o} 135 |i79 | 232 | 281 | 333 | 3a2 | 435 | 486 | 515 96.2|149 |198 | 256 | 311 | 368 | 422 | 481 | 538 | 569 ios | 164 | 219 | 283 | 343 | 406 | 466 | 531 | 594 | 629 16 [179 | 238__| 309 Kus 443_| so9_| s7o_| 648 | 686 jae | iss} s50 | 336 | 207) 461 [ses [630 | 70a | 745 137 | 212 | 263 aaa | 525 | 603 | oa7 | 763 | 813 150 | 232 | 308 4e4; 572 | 657 | 749 | 837 | 886 162 | 251 | 333 524 | 620 | 712 | 811 | 906 | 959 175_| 271 361 Dwi se7_| 670 | 770 _| 077 _| 980 _| 1040 Tag} 292 388 S503 | 610 | 72i | 626 [943 |i0s0 | 1120 203 | 314 A) 540 | 656 | 775 | 890 |1010 | 1130 | 1200 217 | 336 | 4 sig | 702 | 830 | 953 |1090 | 1210 | 1290 232 | 359 is sig | 750 | ga? |1020 |1160 | 1300 | 1370 dle aS O@ ORK OD OolA DOOD LOO OR NOD OIE LOD O)RNO® OG 247 | 382 og | 669 | 799 | 945 }1090_|1240_ | 1380 | 1460 365) 407} 542 | 702 | 851 1010 [1160 [i320 [1470 | 1560 276 a 567 | 734 | 891 |1050 |1210 }1380 | 1640 | 1630 208 | 4 612 | 793 | 962 | 1140 11310 |1490 | 1660 | 1760 315 | 487 | 648 | 839 |1020 {1200 |1380 |1580 | 1760 | 1860 333 | 515 {686 | g88_|toso_|1270_ [1460 |1670 | 1860 | 1970 35a | 844 | 724 | 936 [1140 1350 [1550/1760 ; i970 | 2080 307 | 56a | 755 | 978 |1190 11400 |1610 |1840 | 2050 _| 2170 301 | 608 | 604 ]1040 ize {1600 [i720 [ise [ais | 2310 SS Ss en re ee a TABLE 4.2TM 9.3.11 page 14 _ STEEL PIPEWORK EXPANSION See Nov 72 : L 4.2 Expansion of a steel pipe double bend Contd. = S Allowable dimensions for # = 2.0 A : Delp 4 Lh D a b all in consistent units A PIPE TEMPERATURE Fr a TS 76 | 264 | 320 | 360 ] 902 | 410 1001 120_| 140 | iso] 180 2i0 33.4 27.8 20.0! 25.9 : 20.0! 25.9 { +3] 20.4) 26.3 Ti 87.3 21.5; 27.8 22.9, 29.6 25.1! 32.5 27.3 | 36.3 29.5) 38.1 32.1 | 41.4 35.0| 45.2 36.8] 47.5 39.0 41.2 43.0 45.5 At. 49.9 62.5 55.4 87.5 60. 62.7 ee eh 70.3 72.8 15.4 77.6 80.5 83.4 85.6 88.1 30.7 93.6 36.2 TABLE 4.2.5TM 9.3.11 page 15 STEEL PIPEWORK EXPANSION Nov 72 e double beng Contd. 4.2 Expansion of a steel Anchor loads due to expansion §-2.0 A 'D.e/p EL ‘Thrust F = K (g-+qgr-) Where F = thrust at anchor TF x10 : E = modulus of elasticity Ee I = moment of inertia of cross section L=length (All in consistent units) PIPE THMPERATURE 3 0 v: 23,2] 80.9] 40,0] 21.8) 29.0) 37.6 22.2| 29.6] 38.3) 23.4) 31.2 40.4) | 25.6) 34.1] 44.2 31-1] 41.4] 53.6 35.6) 47.4] 61.4 40.91 54.4] 70.5) 48.5) 64.5| 83.6 55.9| 74.3] 96.3 $3.6} 8.7 | 110 72.2| 96.1] 124 ai.4| 108 | 140 91.3] 122 | 187 102__| 136__| 176 Tig] ist [195 125 | 168 | 215 136 | 181 | 234 150 | 200 | 259 164_| 219 _| 288 7s | 337] 307 193. | 287 ail | 281 229 | 304 248 | 330 266 | 354 285 | 38 307 326 346 36 387 408 438 460 465 520 353 —_ TABLE 4.2.6TM 9.3.11 page 16 STEEL PIPEWORK EXPANSION Nov 72 4.2.7 Cold draw with double pipe bend The procedure set out in 4.1.3 for single bends applies. EXAMPLE: Given a double bend where = * 1-0 and 1, = 70D at a working tdinpera- ture of 180 °C, Required to find: (a) values for h ‘without and with 50% cold draw (b) amount of cold draw when installed at 20 °C (a) Without cold draw, from Table 4.2.1 L_ for pipe temperature 180 °C and py E_s70 is 4 approx D With cold draw, fictitious temp. Tp, from Table 4.1.3 is 100 °C L ‘Then from able 4.2.1, F- for 100 °C and L D= 70 is 4.5 approx (b) Amount of cold draw at 0 °C, from Table 4.1.3, col. 3 co = tet x top = Se p 85.2 p (3 Ge) -Ta In this instance, the graph of — against Ta would be :~ 4 Coy Fig. 2 10 2030 Ambient tomp *eTM 9.3.11 page 17 STEEL PIPEWORK EXPANSION Nov 72 Expansion of a U-shaped steel pipe loop Allowable dimensions Lh W D all in consistent units TEMPERATURE 80°C - 176°F TABLE 4.3.1/1—— TM 9.3.11 page 18 STEEL PIPEWORK EXPANSION Nov 72 4.3 Expansion of a U-shaped steel pipe loop Contd. jw | Allowable dimensions L h W D alkin consistent units ‘TABLE 4.3.1/2 TEMPERATURE 120°C - 240° WD pe io ay 20 25 fo 40 PWAXIMUM VALUE OF 1 TABLE 4,3.1/3TM 9.3.11 page 19 STEEL PIPEWORK EXPANSION Nov 72 4.3 Expansion of a U-shaped steel pipe loop Contd. D 10 15 20 30, 40 350, 60 70. 80, 20 Allowable dimensions Lh W D all in consistent units TABLE 4,3.1/5TM 9.3.11 page 20 STEEL PIPEWORK EXPANSION Nov 72 4,3 Expansion of a U-shaped steel pipe loop Contd. Allowable dimensions Lh W D all in consistent units TABLE 4.3.1/6 < TEMPERA PURE 210°C - 410°F Pee T= Te Te T= ]- RRIMUMTVA Bpalelelela oI sgsssgi ab aSelse TABLE 4.3.1/7TM 9.3.11 page 21 STEEL PIPEWORK EXPANSION oa Nov 72 4.3 Expansion of a U-shaped steel pipe loop Contd. Anchor loads due to expansion Thrust F=K( pete) where F = thrust at anchor E = modulus of elasticity I = moment of inertia of cross section D = pipe outside diameter (All in consistent units) TABLE 4.3.2TM 9.3.11 page 22 STEEL PIPEWORK EXPANSION Nov 72 4.3.3 4.3.4 EXAMPLE of the use of Table 4.3. 1:~ Find the minimum number of loops required in a pipe line operating at120 °C of total length 3 600 D, if the maximum offset h which can be accommodated is 36 D. (a) Consider 6 loops. ‘Then L = 600D and n= 6 Suppose % = 10. ‘Then from Table 4.3.1, 8 = 48. {b) Consider 9 loops. | ‘Then L = 400 D and n= 4 w h At B= 10, from Table 4.3.1, 5 = 37. ‘Thus 9 loops whose W = 10 meet the design requirement, NOTH that if loops with © = 30 can be accommodated, when a = 6 4 22.36. ‘Thus 6 loops whose f= 30 also meet the design requirement. Cold draw with U-shaped pipe loop w ‘The length of pipe per loop is known, and a value for jy selected. From the example above, it is seen that we arrive at a value of h/D corresponding to the selected value of W/D and the value n determined from n = L/100D, When applying 50% cold draw, we use a value of a/2 EXAMPLE: Using the layout in 4.3.3. (2) above, n = 6 and thus a. Wee bh -3t. 2-3. Then for Y= 10, B = 31 To calculate the amount of cold draw to be applied, the total pipe gy , expansion from 0 °C is determined from Table 2.1 (i.e. expansion = 11) ‘The amount of cold draw to be given, at an installation temperature of oa 0 °C, is one-half of this, i.e., c, « £Txu a 2 x 108 and, as set out in 4.1.3, this must be adjusted Zor the ambient temperature Ta at the time of installation by using the formula Cp, °% (To-7a : Ta Goa Gt) where Ty, is the design D working temperature Considering further the example 4.3.3 (a), at 120 °C € = 1.483 1,483 x 600D L: 600 D Expansion =~ To" = 0.89D ‘Then cold draw at0°C CC, = 0.445 D.TM 9.3.11 page 23, STEEL PIPEWORK EXPANSION Jan 81 rev 1 4.4 A steel branch at right angles to an expanding main ‘Table 4.4.1 below gives the required value of Lm of unrestrained branch off a main pipeline expanding x mm. LiD N YCUNS HAD: 6) Nominal Size oom Fig. 3 NOTE that (1) the branch may be welded into the main or a screwed lee used; (2) the pipes may be horizontal or vertical; (8) it is assumed that the end of the branch away from the main pipeline is guided, with the main rigid laterally. Alterna- tively, the branch could be anchored at the guide position shown, provided the mains were flexible laterally. In either case the axial expansion of the branch must be considered separately, using the data in 4.1 - 4.3 (4) the branch pipe between main and guide must be supported either on hangers whose lengths accord with TM 9.9.13, or on sliding supports which allow both axial and lateral movement. Branch ‘Minimum unrestrained branch length L metres nominal for main pipeline expansion of x mm size damm | 5 | 10 | 15 | 20 | 25 | 30 | 40 [2 60 | 10 | #0 is | t.0/1.6]1.5/2.0|20/25 [25/30] 30] 35 | 38 20 | 1.0)/1.5}2.0]25 ]25] 30] 35 ]3.5| 40] 45] 45 26 | 1.0]/20]2.0)2.5 |30]3.5 | 40] 4.0] 45 | 5.0] 5.5 a2 | 1.5/20]25]3.0 3.5 | 35] 40]5.0] 5.5] 5.5] 6.0 40 | 1.5]2.5]30]3.5 13.5 | 40} 45 | 5.5] 6.0] 6.5) 65 so | 2.0/2.5/3.0/3.5/40]45|5.0]60/ 65] 70] 7.5 65 | 2.0/3.0]/3.5]4.0]45 | 5.0] 6.0] 7.0] 7.5] 8&0] 8.5 go | 2.5]3.0/4.0/4.5 | 5.0] 6.0} 6.5] 7.5] 80] 85) 95 aoo | 2.5/3.5]4.5]5.5 | 6.0] 6.5 | 7.5 | 6.5] 9.5 ]10.0 |11.0 125 | 3.0/4.0]5.0]6.0 | 6.5 | 7.5 | 85 | 95/105 [11.5 } 12.0 iso | 3.5/4.5/5.5]6.5 | 7.5 | 8.0] 9.5 10,5 ] 11.5 | 12.5 ) 13.0 2oo | 4.0] 5.0/6.5] 7.5 | 8.5 | 9.0 }10,5 |12,0 | 13,0 [14.0 | 15.0 250 | 4.5/6.0] 7.0] 8.5 | 9.5 |10,0 |12,0 |13.5 | 14.5 | 16.0 | 17.0 soo | 4.5|6.5| 8.0] 9.5 [10.5 11.5 |19,5 }15.0 | 16.0 | 17.5 | 18.5 [For values of x greater than given in this Table, use the equation Lad. 1 Vea fapydtes fer topper de ad eveuerebaons opbe ade” fy " : ‘ 85 TABLE 4.4.1 Fa en,TM 9.3.11 page 24 STEEL PIPEWORK EXPANSION Jan 81 rev 1 Cm By 4.4.2 Cold draw ‘Table 4.4 is based on the branch being unstressed with the pipeline cold, Twice the amount of expansion ( x ) can be accepted for the given value of L if 50% lateral cold draw on the branch is specified on the working drawings and applied on erection, 4.4.3 Lateral thrust at guide or anchor ‘The lateral thrust due to sideways movement of the branch is given by: (1) For pipes on hangers T = (0,024 Py) +0,57Ld oe (2) For pipes on supports T = (0,0024 » +1,15 Ld z 5 (3) For pipes on supports . ite 8 Fe ee nes oT = (0.0024 TF) + 0,25 Ld g 7 6 where T is lateral thrust N S x 4s expansion of main mm a L is unrestricted length of branch m e dis nominal bore mm 3s I is moment of inertia of branch mm* cee toppes, Talle oranzi becnwes 4.001E i akane Ines ve Cando =; Eats) Th fh 2 2 wold) po o02d bx. Be aroond LOOMS tha BDZ o ond Tx Bad a area aiid tbat) ay bee a4) See eee peed om atk tas bo ye ann yad + chee melee aE formy catafay TM 9.3.11 page 25 STEEL PIPEWORK EXPANSION Jan 81 rev 1 4.5 Expansion of vertical risers 4.5.1 Special considerations ‘The special problems associated with vertical pipelines ia multi- storey buildings are - (1) The need to keep vertical shaft areas economical. To meet this, the pipeline will normally be kept straight, without loops to absorb expansion, and will be dealt with as one continuous length. (2) The method of carrying the weight of the full pipeline. Two situations require consideration: a. where the pipe size does not increase with height. In this case, the complete weight of the full pipeline is preferably carried at the bottom of the shaft or, for smaller risers, bracketed from the first slab. ‘This avoids the complications of load-bearing brackets in the height of the shaft. The riser is then allowed to expand freely upwards through guides, whose spacing is calcu- lated from the data(in-para-4.-5-2-and)Table 9.1. b. where pipe size increases towards the top of the riser, as would occur with roof-level boiler plant. ‘The smaller pipes at the foot of the riser may not be sufficiently rigid, and the load must then be carried, at least partly, from anchors above or on the sides of the shaft. : ‘The maximum load on the base is the sum of * (the total weight of full insulated pipeworl in the riser and the horizontal branches between riser and first support) © HADEN YOUNGS LTD- plus (friction at the guides on the riser) plus (downward thrust of all the branches under maximum deflection due to expansion) The riser guide friction (yj) = 1. 15Ha where H is rider height m dis weighted mean nominal bore = mm or 0,25Hd if PTFE inserts are used ‘The downward thrust’ of the branches is the value of T calculated as in 4.4.3, ‘The minimum load on the base is (the total weightof empty pipework in the riser and the horizontal branches between riser and first support) Jess (the upward pull of all the branches under maximum deflection “—~ “due to cold draw) * ie, mass (kg) x 9.81 m/s? = N ‘See TM 9, 9,11TM 9.3.11 page 26 Sam STEEL PIPEWORK EXPANSION a Nov 72 4.5 Expansion of vertical risers Contd. (3) The need for flexibility of connections to branches at each floor. The vertical movement of the riser at the level of any branch must be absorbed by the flexibility in the branch; for riser heights H up to 30 m on LTHW or 20 mon HTHW or steam, it will often be possible for the necessary movement to be accommodated by the branch pipe. Use Table 4.4.1 to determine the offset needed, and apply 50% lateral cold draw to the branch to obtain maximum advantage. Note the need to consider also the axial expansion of the branch. ‘The maximum guide spacing for risers should conform to Table 9.1. © Where the flexibility of the branch is inadequate, a pair of =, hinged bellows joints will be required. For design data, see section 7. 3 Z 4.5.2 Guide spacing 5 ¢ z 5 7 5 3 4.5.3 Riser diagram In order to show clearly the design and installation details, a riser diagram should be prepared for all vertical pipelines where expansion has to be considered, The diagram must show, for each vertical pipe: - (1) Heights and pipe sizes. (2) Positions and sizes of branches. (3) Unrestrained length to first guide or anchor on each branch. (4) Cold draw on each branch. (8) Guide spacings on riser. ~ (6) Maximum and minimum base loads. (7) If anchors are required other than at base, their positions and (8) Working pressure and temperature. loadings. An example is given in Fig. 4, opposite.page 27 STEEL PIPEWORK EXPANSION om 9, 3.11 Nov 72 jeter — wvic Gio HER @ oe WD GLI DNATA ravw © Vad C10 GOREN Fig.TM 9.3.11 page 28 STEEL PIPEWORK EXPANSION Jan 81 revi 5. Additional anchor loads from friction over guides and supports The Tables in section 4 are used to calculate the anchor loads due to bending, Additional loads arise from friction over guides and supports, which must be added to arrive at the total anchor load, Friction at guides e F,(N) = 1.151d where L is pipe length =m andeHens euros d is pipe size mm or 0, 25Ld for supports with PTFE inserts Friction at hangers whose lengths accord with TM 9, 9.13 BAN) = 0.57Ld ( © 17 ONNOA N3GVH (© HADEN YOUNG LTD 6.2 TM 9.3.11 page 29 STEEL PIPEWORK EXPANSION Nov 72 7 Axial Bellows Design rules (1) Never use bellows where pipe loops can be fixed. (2) Axial bellows must only be used on straight sections of pipework between two anchors. (3) Pipe movement at bellows must be exactly axial,’ with no lateral movement whatever. (4) Never use axial bellows where pipes are suspended. (5) A pipeline fitted with axial bellows must be given first consideration in a piping layout so that guides and anchors can be rigidly fixed to the structure. Details to suppliers (1) Size of pipeline. (2) ‘Type of connections (e.g- Flanged Table_) (3) Working pressure and temperature (4) Test pressure (5) Minimum temperature (normally - 1 °C) (6) Expansion to be absorbed between minimum and working temperatures. A 10% margin should be added to the calculated figure.TM 9.3.11 page 30 STEEL PIPEWORK EXPANSION Nov 72 6.3 Guide spacing Wherever possible, specific recommendations on guide spacing should be obtained from bellows suppliers, and these recommendations Should be adhered to where they are closer than those given in this section. | < SspAcine| OF OTHER Gunes. SPACING OF Fig. 5 an ennot sav @ NB; For articulated joint offsets (where the thrust is not affected by the internal pressure) use the column for 350 mb. 7TM 9.3.11 page 31 STEEL PIPEWORK EXPANSION Jan 81 rev 2 6.3 Guide spacing (continued) : Normally, fix an anchor immediately on one side of the bellows; on the other side fix two guides at the spacings shown in columns (a) and (b) of Table 6.3.1, and thereafter at spacings from the appropriate column (c). Do not use the types of guide indicated in Engineering Appliances Ltd's booklet "Installation Instructions: Axial Angular and Articulated Compen- sators" but refer to TM 9, 9.22, \Do not use guides on both sides of bellows; fix a further anchor on the guided side at the end of the section of straight pipe. het Spacing of Guides ‘Spacing of other guides m size at Bellows Internal pressure bar m mm [lst Guide | 2nd Guide |S. To s (a) (b) (c) (e) (ce) {e) 7 4 15 | 0.050 | 0.380 | 4.0 | 3.0 | 24 | 24 g 20 0.050 0.460 4.9 4.0 | 3.0 | 2.7 3 25 0,050 0.610 5.2 4.3 | 3.3 | 3.0 2 z & 32 0.080 | orto | 6.4 | 4.9 | 4.3 | 4.0 2 40 | 0.060 | o.o10 | 7.8 5.5 | 4.6 | 4.3 & so | 0.080 | 1.070 | 9a 6.7 | 5.8 | 5.2 65 0.100 | 1.220 uw 3.2 | 7.3 | 6.7 80 0.110 | 1.520 12 10 | 6.2 | 7.3 100 | 0.150 | 1.980 15 w |ou o1 1s0 | 0.230 | 2.740 17 13 | 12 re 200 | 0.300 | 3.660 20 is | 14 12 250 | 0.980 | 4.570 28 a | 168 15 300 | 0.460 5.5 32 24 | 20 18 350 | 0.530 6.4 38 26 | 22 19 400 | 0.610 1.3 39 20 | 24 au 500 0.760 9.1 46 33 | oar 24 TABLE 6.3.1TM 9, 3,11 page 32 STEEL PIPEWORK EXPANSION Nov 72 6.4 Working drawings Working drawings must show the test pressure for the pipeline, and at each bellows: (1) the expansion (mm) to be absorbed from -7 °C; (2) the free length of bellows (mm); (3) the cold stretch to be applied (mm) at an installation temperature of 10°C, This should be as given by the suppliers, or in the absence of specific information from them, take as 40% of the expansion from ~7 °C to the working temperature at each anchor - ( (4) the load due to bellows on each side of anchor (see 6. 5); and (5) the positions of guides, These should be as specified by the suppliers, or in the absence of specific information from them, as taken from 6, 3. G11 SNADA NaavH ©© HADEN YOUNG LID TM 9.3.11 page 33 STEEL PIPEWORK EXPANSION Jan 81 rev 1 6.5 Guide design Guides must be designed for lateral strength as well as vertical, The design lateral thrust should be taken as 24% of the design anchor thrust (see 6.6). The design yertical upward thrust should be taken as equal to the lateral thrust, The design vertical downward thrust should be taken as the upward thrust plus the deadweight of the full pipeline. For typical designs, see TM 9.9.22. 6.8 Anchor loads 6.8.1 ‘The anchor must be designed to resist a thrust of ‘y = Compression | friction in internal, of bellows pipe supports * pressure = 70d + 'Li5nd + 0.1 Pa (or as specified by the bellows suppliers, if greater) where T = thrust N d= pipe size mm L = pipe length between anchors m P = working pressure bar a = internal area of bellows at greatest diameter (which is mm? always larger than d) ‘This equation gives the maximum working load from one side only, Under working conditions, the opposing load from the other side will balance some of this, but this is neglected in designing the anchor. During pressure testing the load will be more, but this is provided for in the safety factora allowed in the permissible stresses used in compiling the data in TM 9.9, 21, 6.6.2 ‘The Engineering Appliances Ltd booklet mentioned in 6.3 describes on page 6 the use of "intermediate anchors", These are to be used only exceptionally on very long straight pipelines (say with six or more anchors). Normally (except as stated in 6,6. 3 below) all anchors with axial bellows are to be designed ag main anchors. 6.6.3 Where a succession of similar bellows occurs on very long straight pipelines without valves, sub-anchors may be designed for a reduced net load of 10d + 11,15L'd (or as specified by the bellows suppliers, if greater) Te where T! = thrust N d= pipe size mm L! = pipe length between sub-anchors m "0.25 ta and 0.25 L'a respectively, Sf PEPE inserts are usedTM 9.3.11 page 34 STEEL PIPEWORK EXPANSION — Jan 81 rev 1 6.6 Anchor loads (continued) 6.6.4 An anchor at a change in direction must be designed for the vector sum of the thrust in the two pipe legs where this is more than the load from one side: A Ts. | 1. ts eee "Fig 6 6.6.5 In all cases, anchors designed for the full thrust calculated as in 6.6.1 or 6,6, 4 must be fixed at all changes in direction, main branches and isolating valves, und at both ends of pipework that will be separately tested, 6.7 Erection and testing 6.7.1 Cold stretch ‘The cold stretch shown on the drawings is the amount by which the bellows must be expanded from their free length, after the anchors are secured and the pipeline is at a temperature of 10°C, If the installation temperature is outside the range -1°C to 21°C, connection of the bellows should be delayed, or a reference be made to the office to obtain the revised value for cold stretch. 61.2 Testing (1) No pressure test is to be applied to a pipe fitted with a bellows i until the anchors on both sides of the bellows, and the guides, have been properly secured, (2) Where sub-anchors are used on very long straight pipelines, the main anchors at both ends of the section to be teated must also be secured. (3) The test pressure is not to exceed the value stated on the drawings, a17 Onno, Naan © § 6.8 Thin wall bellows For instructions specific to thin wall axial bellows, refer to TM 9.9, 31. ;TM 9.3.11 page 35 SF STEEL PIPEWORK EXPANSION Nov 72 1 Hinged Bellows and Ball Joints 7.1 Introduction Hinged bellows joints, which afford a controlled angular movement without axial displacement, are available from several makers. Used to form offsets or loops in long pipelines: (1) they can take up large amounts of expansion; (2) they will often be much cheaper than axial bellows with comparable duty; (3) their space requirements are less than those of solid pipe loops or offsets: (4) they impose lower anchor loads than loops, offsets, or axial bellows. Ball joints may be considered as an alternative to hinged bellows. 7.2 Types of joint T.2.1 Double-hinged or articulated joint ‘Two bellows separated by a short length of straight pipe, the ends being tied together with a hinged linkage of steel bars or rods. 7.2.2 Single-hinged or angular joint A single bellows with short pipe ends which are joined together with a hinged linkage. 7.2.3 Ball joints 2 5 o 3 © 2 é e 2 € A part-spherical spigot on the end of a short pipe housed in a socket on a second short pipe, provided with inner and outer gaskets, and retained with a clamp nut. Ball joints allow movement in all planes, and both types of hinged joint may be specially designed to permit this; normally the hinged joints permit angular movement in one plane. 7.3 Application 7.3.1 General Most bellows joints are rated at from 1° to 3° angular displacement per convolution, and.the number of convolutions ranges from three or four to eight or more per bellows. Hence in general terms angular bellows joints require an offset of around 12 to 18 mm- per tm of expansion. Few details of any standard units are published, since most hinged Joints are specials. Details of the arrangement to be used must be agreed with the makers (see 7.4).eM 9.5.11 page 36 STEEL PIPEWORK EXPANSION Nov 72 7 1.3.2 Double~hinged Joint Figure 7 shows a typical application of articulated bellows. ‘The dimensions, while typical, vary with make and type and must be confirmed with the manufacturer. EXPANSION OFFSET WITH pouBLe- GRD {ARPICULATED) JO3NT AS CLOSE AS oss IBLE 20 - 30 DIAKETERS | 12 - 18am Tomas oFrset 0 PER MILLINETRE OF ot : IEEE OF py sn BAEANSEON ui pus BeNts = t ee ay ; COLD DRAK oS | sora : sxPANsTOw Fig. 7© HADEN YOUNG LTD 1.3.3 TM 9.3.11 page 37 ae) STEEL PIPEWORK EXPANSION Nov 72 Single-hinged joint Fig. 8 shows an expansion loop using three joints, and an offset uaing three joints. It is sometimes possible to take up the axial movement in the latter application by the sideways flexibility of the mains, and use only two single hinged joints. Again, the makers’ recommendations for layout and dimensioning must be obtained. BXPANSTON L007 WITH ae 8-12 nm can cin of NOHO : t opessr xr ENOED BELLOWS JOTNTS PER NILLIMRTRE OF BKPANSTONBALL CENTERS TM 9.3.11 page 38 STEEL PIPEWORK EXPANSION Nov 72 1.3.4 Ball joints Figure 9 shows the most usual layout, a typical offset using two ball joints, and also an offset using three joints. A comparison can be made with Fig. 8. The makers should be consulted for specific application data and dimensions. LY BALL CENTERS cOLo-seT—} W : < ee BALL END \ | | BALL END rte oe itt it FOR VERTICAL INSTALLATION ! TURN THIS JOINT OVER WITH | BALL NECK DOWN BALL END Fig. 9 a@L1 ONNOA NaZavH @© HADEN YOUNG LTD 14 18 1.6 aT RUA 112 TM 9.3.11 page 39 STEEL PIPEWORK EXPANSION Jan 81 rev (SEZ) Details to suppliers (2) A scale drawing of the pipeline layout. (2) Size of pipeline, (3) Working pressure and maximum working temperature, (4) Test pressure, (5) Minimum temperature (normally -1°C). (6) Expansion to be absorbed between minimum and working temperatures, A 10% margin should be added to the calculated figur Guide spacing ‘The guide spacing adjacent to bellows joints is indicated on Figures 7 and 8 but should be confirmed with the makers. The spacing of other guides along the main can be taken from Table 6.3.1, using the column headed ‘Internal pressure 3.5 bars (since the thrust is not affected in these cases by the internal pressure). For guide spacing with ball joints, refer to manufacturers, Working drawings After confirmation by the makers, working drawings must give the test pressure for the pipeline, and at each bellowa - (1) the expansion (mm) to be absorbed from -1°C ; (2) the minimum dimensions between the component hinged joints of a set ; (3) the minimum length of offset ; (4) the cold draw to be applied at an inatallation temperature between - 1°C and 21°C. at each anchor - (5) details of type, and the thrust it must resist(see 7.7) and - (6) the positions and types of guides; (7) the method of support to be used for the pipeline, Anchor loads ‘The total anchor load comprises: ‘The force necessary to deflect the hinged bellows joint, This must be stated by the makers; as a rough guide it may be taken as 10 N per millimetre of pipe nominal bore, ‘The total force required to overcome the friction at all the guides and supports between bellows joint and anchor. This can be taken as 1,15Ld for normal supports where 0,25 1d for supports with L = pipe length between PTFE inserts bellows & anchor (m) or (0, 87.Ld for hangers 4= pipe eize (mm) ‘Thus the anchor must be designed to withstand axial and lateral thrusts of approximately 10d + 1, 151d N (or 10d + 0, 25Ld for supports with PTFE inserts or 10d + 0, 57Ld for pipelines on hangers).TM 9, 3.12 page 40 STEEL PIPEWORK EXPANSION Jan 81 9,2 9.4 revi Support Spacing - see TM 9.9, 11 Guide Spacing Guides are required only when it is necessary to restrict a pipe to purely axial movement, and/or to prevent buckling under heavy end thrusts, They are unnecessary on freely-suspended pipework where reasonable sideways movement is tolerable and the end thrusts are small. Guides must NOT be used: (1) for expansion bends and offsets between the anchors (2) on loops between the prescribed guides shown 100 D apart ‘The special cases of guide positions with axial and hinged bellows joints are dealt with in paras 6,3 and 7. 5, In general, the maximum allowable spacing of guides is determined by the axial thrust on the pipe line. For horizontal and vertical pipes, except those with axial bellows, the thrusts are not very large, and a normal maximum guide spacing as the column in Table 9.1 headed 3.5 bars internal pressure can be used in cases where guides are required, ( 417 ONNOA NaavH ©)ap TM 9.3.11 page 41 e STEEL PIPEWORK EXPANSION Apr 73 rev 1 9 Guide Spacing (continued) Guide spacing m Internal pressure bar © HADEN YOUNG LTD 10,5 15 4.0 3.0 2.4 2a f 20 4.9 4.0 3.0 2.7 25 5.2 4.3 3.3 3.0 32 6.4 4.9 4.3 4.0 40 1.3 5.5 4.6 4.3 50 9.2 6.7 5.8 5.2 65 iL 8.2 18 6.7 80 12 10.0 8.2 1.3 100 15 12 n 9.2 168 17 13 12 a 219 20 16 14 12 D 213 28 a1 18 16 324 32 24 20 18 386 35 26 22 19 406 39 29 24 at 508 46 34 20 24 TABLE 9.1Related Topics TM 9.331 Thin wall bellows expansion joints TM 99.21 Design of piping anchors TM 9.9.22 Design of piping guides TM 9.9.23 Bolted fixings for pipe anchors and guides. Post-it Note ‘The main TM section and the related topics give basic information only and are not necessarily up to date, so refer also to: British Standards: Bs 3974 ‘Specification for pipe supports Part 4: 1974 Pipe hangers, slides and roller type supports Part 2: 1978 Pipe clams, cages, cantilevers and attachments to beams CIBSE Guide B Sections B16-1 to 11‘OUNG LTD ADEN ® 3 5. TM 9.6.16 page 1 STRAINERS IN WATER SYSTEMS Feb 82 STRAINERS IN CLOSED CIRCUIT WATER SYSTEMS Most centrifugal pumps do not need fine strainer protection, but many heat exchangers and certain control valves do (see TM 11,1.14). ‘The practice of installing strainers immediately before pumps is almost always incorrect. Strainer blockage is likely to reduce pump suction pressure sufficiently to cause cavitation, especially on heating systems. Strainers should never be used on pump suction connections where the pump head + [1.1 x NPSH] is more than the static pressure of the system at the pump. If a permanent strainer is thought necessary in a closed circuit, it should preferably be upstream of the cold feed connection (ie strainer ‘between pump delivery and cold feed connection, not between pump suction and cold feed connection), so that blockage would result in a rise of pump discharge pressure rather than a reduction of suction pressure, Strainers installed in systems should preferably be fitted with a generously sized blowdown valve that can be used in conjunction with an upstream isolating valve to back-flush the strainer cage. This saves the expensive operation of draining and removing the cage. Note that the design of some bucket strainers does not permit blowdown + these should be avoided. Strainers for steel piped closed water systems should never be fitted with fine gauze mesh. Mesh size should be a minimum of 0.5mm on eizes below 25mm, and perforation diameter 3mm on larger sizes. It is advisable to fit a line size dirt pocket and drain immediately before a pump, to collect any large debris which may damage the impeller. This is easily arranged with the usual vertical suction connection, Strainers are no substitute for proper system flushing + see TM 9.6.13. Jor vert Fee HE oFRelated Topics Refer to the TM sections noted in 9.6.16 Post-it Note ‘The main TM section and the related topics give basic information only and are not necessarily up ‘0 refer also to: Application Guide 1/89: flushing and cleaning of water systems ‘Application Guide 8/91: Pre commission cleaning of water systemsKID Hi TM 11.1.16 page 1 THERMOSTATIC VALVES Aug 85 rev 1 IC VALVE! 4 duction la Individual control of heating terminal units is achieved effectively and economically by direct acting (ie self-operating) thermostatic valves. i These are cheaper and more reliable than the smaller electrically operated valves. The control quality and operating economy of a correctly designed system with room thermostat control on terminals are better than those of a system with outside compensator control. 12 The sensing elements of direct acting valves have high thermal capacity, and will not respond quickly to rapid changes of air temperature. Most types are not available with reversible action, ‘They are therefore not suited to many air conditioning applications. 2. Positioning aa The sensing element should be in a position representative of yoom conditions. Radiators with one-piece thermostatic valves should have BOE connections as this will minimise the effects of sun and convected heat from the flow connection on the sensing head. 2.2 Where full-length curtains are likely to cover the valve head, remote sensors should be used. 3. Hydraulic Design 3a Two-port control implies variable flow and variable head ; these should be catered for in the hydraulic design. See TM 6,2.34, @ HADEN pic 32 Direct acting controls require a stable pressure differential across them to ensure good control quality. If the pressure difference builds up as the valves throttle, the rise in room temperature required to close the valve will increase. If the pressure differential limit for the valve is exceeded, effective control ceases. To avoid noise problems, the pressure drop across a thermostatic radiator valve should not exceed 50 kPa. 3.3 Compensated temperature systems may be used in conjunction with direct acting controls. This will reduce mains losses, and reduce but not eliminate the increase in pressure differential at low load. Constant temperature systems, however, are quite satisfactory if the design sequence given in TM 6.2.34 is followed.TM 14.2.11 page 1 ANTIFREEZE MIXTURES B Aug 84 rey 1 ANTIFREEZE MIXTURES Introduction ‘Aqueous Glycol solutions are commonly used when a liquid freezing point lower than 0°C is required eg a) in association with closed circuit cooling towers to prevent freezing of the pipe grid in winter b) in liquid chilling systems where low temperatures are required and as an alternative to the use of brines. Several types of Glycols are available but normally the solutions used will be Ethylene Glycols, though where the use is in connection with the food industries Propylene Glycols should be used. Ethylene Glycols should only be used in the form of inhibited solutions (sce para 4 for recommended types). It should be noted that the use of Glycols will drastically reduce the capacity of plant when comgared with the same plant using water only, typically by 12% for a solution of 20% by weight (see Appendix). Properties of Glycols Glycols are normally sai. to handle but reference should te wade to manufacturers! advice. Undiutec Glycels are not corrosive and can be contained safely in mild ste. tar 3. If storage is prolonged, however, trace contamination by iron from a steel tank may cause slight coloration. It is therefore recommended that | !ycols are to be kept for wore than a few weeks, the storage tanks should be lac cr-lined or fabricated in aluminium or stainless steel, Aqueous solutions of Eth, .cne Glycols corrode most metals and, even though inbibited solutions are use, when stored it is desirable (hat the tanks should be constructed from the materials listed above. Glycols are penetrating Ouids, and difficulty is sometimes experienced in making screwed connections sufficiently tight to prevent leakage. It is therefore recommended that all joints that cannot be welded should be flanged and fitted with gaskets made of asbestos or other suitable materials. Glands and packings should be as few as possible and suppliers should indicate ccmpatibility and leakage rate. Fig I shows the variation of freezing point of aqueous solutions of Ethylene Glycols with concentration. £ TEMPERATURE (°C). 2040 SSCO ETHYLENE GLYCOL (%8Y WEIGHT). FIGA. Freezing points.‘TM 142.11 page 2 ANTIFREEZE MIXTURES Mar 81 solutions Fig 2 shows the variation of Speci of Ethylene Glycol with concentration of sclution, ( SPECIFIC GRAVITY (204/20%C), & +00 020 7 ETHYLENE GLYCOL | oY Weis FIG.2. specitic gravity. ad NagvH @ :.4e0us solutions of Pig 3 shows the variation of Speci..c raz... of solution, Ethylene Glycol with temperature anc. ~ne Ie » 1 SPECIFIC HEAT (4u/9.°C), 02040 $0 80 100 120 140 160 180 Temperature (°C) FIG. 3. specitic neatTM 14,2.11 page 3 ANTIFREEZE MIXTURES Mar 81 Fig 4 shows the varietion of Viscosity of aqueous solutions of Ethylene Glycol with temperature and concentration of solution, Q 100 9 q 0 zr E 5 § Bor 0-99 708 veo ine “TEMPERATURE (°C). FIG.4. viscosity. Reference should always be made to manufacturerst data for a 2 specific Ethylene Glycol when considering the effects of its use. Z «~~ Typical System Arrangements 2 Figs 5 & 6 show a typical arrangement for use of antifreeze iat solutions with a closed circuit cooling tower. cst p—L-yai setae i Seton = = raga i, panic ne epee edn leeun — itrtems. rower [verso rae taanket oman} FIG.S. pisgramatlo ora" foryaoet entfteere solution FIG.G, Diegromatic as fig 5 for pr 16.5. poorer wr ocd eechag weteremaat en FIG.G. ps for einai <4 4 Tanne tan, {Dann reour swTM 14.2.1 page 4. ANTIFREEZE MIXTURES Aug 84 rev'l : 4. General The normal recommended minimum solution strength for use in cooling water systems is 20% by weight and 178 by volume, giving a solution freezing paint of -8°C. It is recommended: that where antifreeze mixtures are required corrosion inhibited, Ethylene Glycol such as ICI Ltd's Thermocal B should be used. If any form of water treatment is to be applied to systems containing Glycols then the treatment supplier should be fully advised about the Glycol being used and all water treatment chemicals must be compatible with the Glycol. All systems containing antifroeze mixtures should have clear and promirient labels giving details of the contents, including the required specific gravity, A suitable hydrometer, measuring jar and thermometer should be provided to enable the specific gravity of the contents of the system to be measured. A sampling connection should be provided as shown in Fig 5. Pumps used in systems containing Glycols should comply with the Company Specification as set out in TM 10.1.11, should use mechanical seals as detailed in para 21.5 of that Specification, and be compatible with and suitable for use with the Glycol solution concerned. Valves for use in systems containing Glycol mixtures should be Saunders Diaphragm Type A, cast iron with grade Q diaphragms. As an alternative butterfly valves in accordance with the Company specification (TM 11.2.51) may be used providing the solution contains inhibitors and the temperature is below 50°C, If butterfly valves are required for use in Glycol containing systems with an operating temperature above 50°C manufacturers! advice should be obtained. Generally, manufacturers of valves should be informed of the type of fluid in contact with their product to ensure compatibility of materials. Brines ‘As an alternative to Glycols aqueous solutions of inorganic salts (sodium or calcium chloride) are available. The main problem with these is corrosion ; this can be overcome by the use of suitable inhibitors (eg sodium dichromate). It is also usual to keep the brine slightly alkaline by adding sodium hydroxide. It will be realised that there may be problems with chemical reactions if any form of water treatment is to be used. Sodium chloride brines have a freezing point of -21°C and Calcium chloride brines are limited to -40°C in normal circumstances. Further information on brines and their use is available from HCE. aid NJavH @ {@© HADEN pic o Ratio of frictional Toss in pipe(approx) —1vcol Pipe(approx) ater at 10°C 18 a? 1a 13 Le LL TM 14.2.11 page 5 E MIXTURES APPENDIX : Pressure Drop and Heat Transfer General “Solutions of ethylene glycol in water, at appropriate concentrations, are sometimes used for frost protection when piping systems are exposed to outside weather in winter or when unusually low fluid temperatures are needed for technical reasons. ‘The rate of pressure drop through the system, and hence the pump head, can be much greater for water-glycol solutions than for ordinary water. Heat transfer rates are also significantly different for the normal conditions of turbulent fluid flow inside pipes and heat exchangers, and dramatically different for laminar flow. The ratings of heat transfer equipment (such as cooling coils, closed cooling towers, plate heat exchangers, condensers and evaporators) must take this into account. Increasing the strength of the glycol solution allows the mixture to be operated safely at a lower temperature before a slush and then a solid is formed. Using more glycol and lowering the temperature increases both the density and the viscosity. Since the latter increases more rapidly the Reynolds number tends to reduce, leading ultimately from familiar turbulent flow to unusual laminar flow. Pressure Drop Rates erase The physics are fairly complicated, but provided that laminar flow is avoided (ie Reynolds number remains above about 3 500) the factors given in Figure 7 can be applied to the ordinary pressure drop rates for water flow at 10°C in medium weight black steel piping. For all practical purposes Figure 7 can also be used for copper and galvanized steel tube. 40% ethy}ene glyco? in water 2-20" i \ 1 ! = Laminar flow 40% ethylene Glycol Interpdlation fin water : 20%) difficult for Tntermediate concentrations I tet EL \ 30% ethylene glycol jn water: -10°C Interpolation possible for | Intermediate concentrattons 20% ethypene glycpt in water : Om 40, 60 30, 100, 120 Pipe internal di r 200 Ez mh 1! 4 1 fim stan sane om fo 152025 3240 50 65 80 100 125 150 Medium weight pipe size mm Figure 7 Pressure Drop FactorsTM 14.2.1 page 6 ANTIFREEZE MIXTURES, Aug 84 ‘The Reynolds number (Rg) should always be calculated for glycol solutions to make sure laminar flow is avoided. Re =vdp where v = mean pipe velocity mls # d= actual internal pipe diameter =m = density of water-glycol solution kg/m? = absolute viscosity of solution —- Ne/m? Table 1: Properties of Ethylene Glycol/Water Solutions Foouing porn Temperature C 15 Density kg/m? 999.7 Absolute viscosity Ns/m* | 0.003 21 |0.003 25 | 0.005 50/0.016 00 Tie water Example. Determine the type of flow and the rate of pressure drop for a 208 solution of ethylene glycol in water, at 0°C for 25mm nominal bore heavyweight black steel pipe at a mean velocity of 1 m/s. (i) From CIBS Table C4.4 > d = 0,0257m From Table 1 above, p = 1008 kg/m? and y = 0,003 25 Ns/m? ‘Then since v= 1,0 m/s we have © 1.0 x 0.0257 x 1008 _ = R, 0.003 25 sauet > o Hence the flow is turbulent. m Gi) From CIBS Table C4.17 (page C4-33), the pressure drop rate for water ag at 10°C in heavyweight tube is 560 Pa/m. a From Fig 7, the glycol correction factor for a 20% solution is 1.22. a Hence the pressure drop rate for a 20% solution at 0°C is $60. x 1.21 = 678 Palm ~ For all practical purposes this would also apply to medium weight steel tube, For the case of copper tube a similar procedure is followed, using the appropriate CIBS Tables. 3, Heat Transfer Duties “for turbulent flow inside copper or steel tubes there can be a considerable reduction in cooling capacity. Figure 8 illustrates typical approximate changes in capacity as the concentration of glycol in water is increased, to permit reduced fluid mixture flow temperatures to an air cooler coil. 100 z gee ses Figure 8 Typical relative cooling g55 capacities for an air gee cooler, coil tile a 7 35 /s face velocity gig? 3 320 fins/metre geez a : 6 rons BEES # ee bebezeeteceeaneeee “10 © “10 Texp of futd in pipes °c When glycol is used in submerged evaporators it is quite possible for laminar flow conditions to prevail with an even greater reduction in capacity, The ae manufacturer may not be aware of this and the possibility should be drawn to his attention,TM 14.7.11 page 1 FRIG PLANT CYCLING Aug 82 FREQUENT CYCLING OF WATER CHILLERS i Introduction 1 ‘A compressor will cycle on and off if the primary cooling load ot applied to the machine is less than the compressor minimum capacity ; if the primary cooling load falls within the range of a step of capacity, ; that step will cycle on and off, One cycle is taken to comprise starting; the period in which the compressor is running; stopping; the period in which the compressor is idle, Ina machine fitted with multiple compressors any of the compressors could cycle on and off, For centrifugal and screw machines fitted with an infinitely adjustable loading mechaniem cycling can only occur when the load is below the minimum operating capacity of the machine ie usually between : 10-15% of full machine capacity. “in general terms no more than six starts per hour should be 12 allowed, this number decreasing with increasing machine size, Zz 2, Calculation of Cycling Frequency a 2.1 Symbols a F = Frequency of cycling of the machine (starts /nour) <= Q = Capacity of the largest initial step of any compressor (kW) ta = Allowed temperature swing of primary chilled water (°o) © W = Weight of water in the primary circuit (xg) V_ = Volume of water in the primary circuit (at) : S = Specific heat of water («a/eg *0) 2,2 Frequency 4 Cycling frequency depends on “ (i) the difference between the capacity of the compressor (or the capacity of the step in which the machine is working) and the load applied (ii) the mass of water in the primary circuit (which determines the cycle time) (44) the value of ta , which is determined by controls (rarely more than 1°C), ‘The highest frequency of cycling is given by 900Q SWta 3. Limitations on Cycling Frequency ‘The number of starts allowed per hour may be limited by several factors. Too frequent starting may lead to: (i) Contravention of electricity supply regulations and agreements (i) Burn-out of the compressor motor Fe _. {ili)_Excessive wear on machines (iv) Noise nuisance (v) Maximum Demand calculations may adversely affect electricity costs. These factors will vary according to the specification of the machine, i the application and the location, FeTM 14 Aug 82 741, page 2 FRIG PLANT CYCLING R 4, 4.1 4.2 Prevention of Frequent Cycling Frequent cycling can be prevented by ensuring that the primary chilled water circuit has gufficient thermal capacity, ‘The minimum volume of water to achieve this is given by: _ 0.9Q VPS ta Example A packaged chiller has a maximum capacity of 210 kW, and five steps of capacity: 70, 105, 140, 175, 210 KW. ‘These capacity ratings apply when the plant is chilling water from 12,1 to 6,6°C, It is operating in a primary chilled water oirouit of total capacity 1500 kg (1, 5m), and a 1°C temperature swing is allowed by the control thermostat. The electricity supply authority permite 6 starts/hour. ‘The specific heat of water is 4,187 kJ/kg °C. In this case the largest step of capacity is the first, of 70 kW; all the other steps have a capacity range of 35 KW. If the first step were not the largest, using the larger step in the calculation would result in the provision of more storage than is necessary. Thus = 900Q@_ , _900_x_70 = F TSW te TisTx 5001 ~ 20 starte/hour ‘This is too frequent, and hence storage of chilled water will be necessary. The minimum volume required in the primary circuit is given by = 292 , 09x70 | Vr rst, Sea ieTaT 7 252m? (2510 ke) ‘Thus additional storage of (2,51 - 1, 60) = 1,01 m? of chilled water is required, This can be in increased pipe size, but if a vessel ig necessary it can be in either flow or return to suit the plantroom piping layout. od NaawH ©Related Topics TM 6.2.25 Chilled water storage for load copping TM 9.13.11 Company specification for chilled and cooling water pipework TM 11. 2.11 Standard chilled and cooling water valves TM 1441.21 Refrigeration plant safety TM 144.11 Specification for reciprocating refrigeration plant TM 145.11 Specification for centrifugal water chillers ‘TM 146.11 Spocification for screw water chillers Post-it Note ‘The main TM section and the related topics give basic information only and are not necessarily up to date,@© HADEN YOUNG LID TM 18, 1,11 page 1 USE OF INSTRUMENTS Jul 78 rev 2 MEASUREM. NT OF TEMPERATURE, RELATIVE HUMIDITY AND AIR MOVEMENT IN ROOMS Room Temperature "Room temperature" is frequently referred to, but rarely precisely defined. The comfort of an occupant of the room is affected about equally by air temperature (t,) and mean radiant temperature (MRT). See TM 1.2.31 para 2. The comfort or resultant temperature (= 0.5 ty + 0.5 MRT) is not registered on an ordinary mercury-in-glass thermometer, The environ- mental temperature (> 0,33 ty + 0,67 MRT) is not measurable directly by any instrament. Air ‘Temperature Where air temperature and MRT differ, an average glass thermometer with a normal bulb when freely suspended in still air will give a reading between the two, Approximately ‘thermometer = 0. 73 ty + 0.25 MRT ‘To obtain a true air temperature, the thermometer must he either (1) shielded from radiation with polished metal foil or (2) whirled rapidly (see para 6. 3) Resultant Temperature Resultant temperature is registered, in still-air conditions where the velocity is less than 0.1 - 0,12 m/s, by a globe thermometer. ‘This is, usually, a mercury-in-glass thermometer with its bulb at the centre of a blackened copper sphere. This sphere is traditionally 150mm diameter, but BRE research (1978) indicates that a sphere about 40 mm diameter is better. A globe thermometer is not appropriate to measure human comfort at higher air velocities ; either the Equivalent Temperature or Effective ‘Temperature scales should be used. ‘Typical Values of Glass and Globe Thermometer Readings Figs 1 and 2 show the responses of glass and globe thermometers and a man to two different environments. The temperatures are typical of those obtaining in a normal room with one outside wall and window, in cold weather with the room unfurnished, when heated by convectors: (Fig 1) or floor panel (Fig 2).TM 18, 1.11 page 2 USE OF INSTRUMENTS Nov 72 2 Temperature “Cc 19 18, ‘Temperature °c 20.5 20 ig UMPERATURES IN CONVEC LION HEATED RUOM wiG.L oT ( GLAss THERMOMETER PIG-2 PEMPERACURES IN RADIANT. HEATED KOOMGil ENNOA NaIgvH @ 4.2 5.1 5.2 5.3 5.4 5.5 TM 18.1. 11 page 3 ae USE OF INSTRUMENTS ary, Nov 72 Note particularly that the glass thermometer (unshielded and stationary) will read 21 °C in the convection-heated room and 19.5 °C in radiant-heated room, although the comfort temperature in and heat loss from the rooms are substantially the same, ‘The effect of furniture and occupants would be, in both cases, to reduce the difference between MRT andt,. When the outside temperature is higher the difference is also less Surface Temperature A thermometer of any kind in contact with a surface (unless it is a fine wire thermocouple brazed or welded to the surface) will always read lower than the true surface temperature. ‘This is due to heat conduction away from the sensing element, and to relatively poor contact. If the object of the measurement, e.g. on pipes or radiators, is the water temperature, even the true surface temperature will be lower. ‘Bie size of these errors varies, but is usually proportional to the difference between the measured temperature and the temperature of the environment. ‘The true water temperature ty, can be expressed as the instrument reading t; plus some fraction k of the difference between that reading and air temperature tg: t i +e (ty - fa) 'w For a fine wire thermocouple taped carefully in place, the value of k0,1, For an ordinary glass thermometer attached with a small blob of plasticene and taped down, k may be anything from 0. 25 to 0. 33. ‘The most convenient instrument for this type of measurement is a contact thermometer such as the Thermophil. This has a metal probe with a very small sensing element at the tip. Carefully used with the probe perpendicular to the surface, contact thermometers have a fair degree of accuracy and consistency, with k =~ 0, 2, but the accuracy is commonly much worse than this. ‘The following Table summarises the corrections applicable to the measuring methods in 5.3 and 5.4, and shows the probable order of accuracy attainable when care is exercised. ‘Accuracy 0,02 (ty = ta) Method ‘Thermocouple taped on ig-in-glass thermometer attached with plasticene t+ 0.3 (y - ta) | + 0.10 (ti - ta) = =o ROR te) Teor cy ty Contact thermometerTM 18,1,11 page 4 USE OF INSTRUMENTS - Nov 72 sf 5.5 6.1 6.2 6.3 6.4 Ta Because of the lag of the instrument, at least one minute should be allowed, for all methods, for the reading to become stable. For this reason, none of these methods will give accurate spot readings when the water temperature is fluctuating; the error is no greater than that of an immersion thermometer in a pocket. With a periodic temperature fluctuation, the thermal lag will reduce the amplitude of the readings compared with the true temperature. The average value over a sufficiently long time will be as close to the true temperature as a steady state instrument reading is to the true steady temperature. Relative Humidity ‘The sling psychrometer is the standard instrument for measuring Ee relative iumidity. Such instruments as hair hygrometers, hygrographs, ete should be calibrated against a sling psychrometer whenever they are put to work. Ideally one should use distilled water for moistening the sock of the wet bulb. In practice, clean tapwater is satisfactory provided the sock is changéd as soon as, it becomes dirty or encrusted with scale from the water hardness. Before the instrument is used, the sock should be checked to see that it is clean and long enough to reach the water in the reservoir. aL) ©NNOA NzavH © ‘The sling psychrometer should be whirled as rapidly as possible, to provide an air velocity past the bulb of 3m/s, With most instruments, this requires whirling at about 3 rev/s, After 30-40 seconds whirling, the wet bulb should be read immediately, then the dry bulb. This procedure is repeated until two consecutive readings coincide. It is important always to read wet bulb temperature first, before it begins to rise. Sling psychrometer wet bulb readings will differ from Meteorological Office published figures; the latter are read from stationary wet bulb thermometers housed in a Stevenson screen out of doors, and are higher than sling figures because the effective wind velocity over the bulb is generally lower. The IHVE Guide tables of Properties of Humid Air (pp C1-6 to 66) quote both screen and sling wet bulb temperatures, Air Movement in Rooms Air velocities in rooms are normally 0.15 m/s or less. Two measuring methods are suitable: (a) the hot-wire anemometer (o) the Kata thermometer© Finwars suns LID 1.3 1A 18 TM 18,1, 11 page 5 USE OF INSTRUMENTS Nov 72 A versatile and robust version of the hot-wire anemometer is the Anemotherm Air Meter which, although expensive, is quicker to use and probably more accurate than the Kata thermometer, Directions for its use are contained in the lid of the instrument case, It is calibrated in imperial units, and readings will have to be converted to SI using the factors listed in TM 16. 4, 12, ‘The Kata thermometer is a spirit-filled thermometer with a large bulb and two temperature marks on the stem, It is used by timing the cooling rate with a stopwatch between these marks, when the pre-heated thermometer is freely suspended, A nomogram enclosed with the ther- mometer uses: (a) the cooling time in seconds {b) air temperature, measured separatoly (c) the Kata factor F engraved on the stem of the thermometer. Three varieties of Kata thermometer are available: (1) With a plain glass (‘black') bulb, filled with red spirit, and calibrated 38 - 35 °C, A silvered bulb may be had to order. ‘This type has an inconveniently long cooling time in warm rooms, and the plain glass bulb is useless for velocity measurement if the MRT and air temperature differ. (2) With a silvered bulb, filled with blue spirit, and calibrated 55 - 52°C, A black bulb may be had to order, ‘This, with a silvered bulb, is the type to use in all normal conditions, (3) With a silvered bulb, filled with magenta spirit, and calibrated 66 - 63 °C. ‘This is the type to use, in preference to (2), in very hot environments (eg in tropical conditions or certain industries), The following precautions should be observed: {a) Do not overheat the bulb; it may break if overheated. (b) Dry the bulb carefully after heating in hot water. Evaporation from a wet bulb will falsify the reading. (c) Take at least three readings at each station, and average them.Related Topics: TM 18.112 Procedures for commissioning mechanical services installations Post-it Note Tho main TM section and the related topics give basic information only and are not necessarily up to date, so refer also to: CIBSE Gulde A: Sections A1-9, Ad and AS% HADEN YOUNG up ( ~ : ™ 8.6. 14 page 1 3 yy CHIMNEYS: ROOFTOP BOILERS Nov 72 2.2 2.21 2.2.2 .UES_FOR ROOFTOP BOILER PLANT =] CHIMNEYS AND Introduction Rooftop boiler plants use CI sectional or MS shell boilers fired by 1! or gas. Available chimney helghts are not normally adequate 1 pr uvicie either the high flue gas efflux velocities required, or the draught requi ry ments for boiler/ burner units of the non-pressurised combust 10n type Advice on plant selection, data on chimney- and flue sizing, &nd notes on construction, are given. Plant_Selection Forced/induced draught fans On CI sectional boilers on oil firing Induced draught fan equipment is required, to provide t he correct conditions, complete with inlet damper controlled from a draught sensor in the combustion chamber to maintain a constant -5, 0 to “12. 5 N/m’. On CT sectional boilers on gas firing CI sectional boilers fitted with a draught diverter at the boiler outlet, and fired by either a naturally inspirated or a blown gas burner need no special fan consideration unless a flue gas dilut ton system is envisaged (see TM 8.6.13), but check minimum chimney height required for combustion requirements from manufacturer. On MS shell boilers, on oil or gas firing Steel shell boilers with pressurised combustion of oi! or gas can generally have the power of the forced draught fan increaserl | provide a residual pressure at the boiler outlet. This pressure should be limited to about + 125 N/m?, which will be sufficient to overcome flue and chimney friction losses and to provide an efflux velocity at full load of 14 m/s. Confirmation must be obtamed fr on’ the boiler/burner supplicr that an FD fan can be supplied to provide this overpressure; the alternative is that an ID fan would be required, Flues and chimneys A separate chimney must be provided for each boiler Flues and chimneys for installations described in 2. 1. 1 and 2. 1. 3 will almost always be operating under pressurised conditions in order to provide the required efflux velocity of 14 m/s or more. Flue and chimney construction for these duties must be all-welded. with the elimination of flanges as far as practicable, Expansion joints should, where cost allows, be of the bellows type. All cleanout doors ets must be of robust construction with adequate clamping devices, and be fitted with graphite-impregnated asbestos seals to eliminate soot- and flue gas leakage. Explosion doors must be of the spring loaded type.T™ 8.6. 14 page 2 CHIMNEYS: ROOFTOP BOILERS Nov 72 2.3 Chimney instrumentation For installations as 2, 1. 1 and 2. 1. 3, smoke density equipment must be suitable for pressurised flue conditons; CO, sampling points, pockets for temperature measurement, etc must be adequately sealed with rammed asbestos rope around the sample probes. 3 Determination of Chimney Height 3.1 Where the building is of equal or greater height than surrounding blocks, Make the chimney outlet a minimum 1. 5 m above the highest point of the roof. 2,2 Where the building 1s lower than one or more adjacent blocks. Preferably : Adopt gas firing. Alternatively: Calculate the chimney height for oil firing as in TM 8 6. 11 paragraph 3. 4, assuming Building Height to be the average rooftop level in the surrounding area, and Building Length infinity. This alternative will usually produce a chimney totally unacceptable aesthetically. 3.3 In all cases Agree the terminal height with the Local Authority. 4, Determination of Flue/Chimney Area 4d Oil fired plant From Fig 8 (CI sectional) or the area for a gas velocity of 9 m/s. 9 (MS shell) in TM 8 6. 11, select 42 Gas fired plant 42d MS shell boilers with pressurised combustion (as 2. 1. 3) Allow a chimney area of 0. 10 m® per MW boller rating. 4.2.2 CL sectional boilers (@s 2 1. 2) Allow a chimney area of 0. 32 m? per MW boiler rating. Chimney Discharge 5.1 To avoid down wash on the roof, a minimum efflux velocity of 14 mis at full load must be allowed. It is achteved by means of a nozzle; for construction details, see TM 8. 8. 21, Figs 1-3Ye © HADEN YOUNG LTD € TM 8.6.14 page i Cm CHIMNEYS: ROOFTOP BO! LE RS. Nov 72 52 The outlet area of the nozzle is calculated as follows: Plant Multiply chimney area by | CI sectional with oil firing (2.1.1) 0.67 Cl sectional with gas firing(2.1.2) 1.00 MS shell with oil firing’ (2.1.3) 067 MS shell with gas firing (2.1 .3) 1.00 53 For plants as 2.1.1 and 2.1.3 either arrange individual chimney terminals with a minimum height of Lm. or fit the 60" wind deflector illustrated in TM 8.6.21 to achieve a clean plume breakaway from the outlet. For plants as 2.1 .2, fit a GC type terminal to each outlet, these allow horizontal air inlet through the vertical louvred sides, 6. Chimney Construction 6.1 Oil fired plants ‘The alternatives which may be used are: 6.1.1 Individual MS welded flues and chimneys aluminium clad and minerad wool, insulated (see TM 8.6.22 paragrapn 6» 6.1.2 Brick construction with 115 mm thick Moler insulating brick linings and 230 mm thick Moler divisions between adjacent compartments. 6.1.3 Conerete construction with 150 mm thick Moler linings and 230 mm | thick Moler divisions between adjacent compartments. 6.2 Gas fired plants As 6.1.1 above.Related Topics TM82.11 Oil fred, gas fired and dual fue! fired boiler selection M8411 Modular boilers TM86.11 Design of chimneys and tues TM86.12 Chimney design for small boiler pian 1M 8.6.13 Fan diluted flue systems for gas boilers, TM86.15 Flues and chimneys for gas boilers TM 86.21 Construction of ste! and masonry chimneys, TM89.41 Checklist for rooftop boiler plant Post-it Note ‘The main TM section and the related topics give basic information only and are not necessarily up to date, so refer also to: BSRIA British Gas: British Standards: BS 5440: CIBSE Guide B: Technical note 2/89: Factors in the design of flues for condensing Boilers and air heaters IMt1: Flues for commerciel and industrial gas fired boilers and air heaters IM1: Automatic flue dampers for use with gas fired space heating and ‘wator heating appliances Installation of flues and ventilation for gas appliances of rated input not exceeding 60kw ‘Specification for installation of flues Specification for Installation of ventilation for gas appliances Sections B13-25 to 98TM 9.2.11 page 1 eer Feb 86 rev 1 BD PIPE SIZING FOR HOT WATER HEATING CONTENTS Page L Introduction a a Application of Full, Approximate and Simplified Methods * 2 3 Pipe Loading Outline of Method 2 Pipe Heat Emissions a Normal 2-pipe Layouts 4 Use of Pipe Loading Sheet 46 Worked example 1 Reversed Return Layouts 9 ° Explanation of method 9 5 Worked example 1213 Approximate Method 15-16 ° PP: 5 3 4 Pipe Sizing 1" > 4.1 Explanation of Method for 2-pipe Systems 1 z 4.2 Corrections to IHVE Guide Main Tables 18 a 4:3 Use of Pipe Sizing Sheet 18-19 2 414 Worked Example 20 = 4.5 One-pipe Systems 23 os 4.6 Systems with Rooftop Boiler Plant 23 ©) 47 Method for a Quick Approximation 23 5. Simplified Method for Small Radiator Systems 24 5.1 Pump Selection 24 5.2 Pump Sizing 24.25 5.3 Worked Example 25 Vepe Haden Score cerperen pregrer “vedtye Heatiey f9 escanetbe te lente Gace C100 capesTM 9.2.11 page 2 HEATING PIPE SIZING Nov 72 2.2 Introduction Starting with room heat loads (calculated as in TM 2.1.11), the pipe sizing process requires two calculation stages a) Pipe loading ie calculating the design water flow rate for each pipe in the system ») Pipe sizing ie selecting the design pipe sizes using the calculated flow rates ‘The pipe loading method to be used, sct out in paragraph 3, is the ‘temperature drop’ method. Application of Full, Approximate and Simplified Methods ‘The full method of loading and sizing should be used for all contracts where the total load is over 45 kilowatts and where the flow increase on the last branch due to flow main temperature drop is greater than 7%. When estimating for these projects, judgement is required to decide whether the full method or the approximate method should be used ; if the order is likely to follow and the system is unlikely to be altered, the full method will be worthwhile. Where the total load is over 45 kilowatts but the flow crease on the last branch is 7% or less, the approximate method of loading given in paragraph 3.5 should be used, followed by the full method of sizing as in paragraph 4. ‘The method for calculating the percentage flow increase is given in paragraph 3.5. For small radiator systems where the total load is less than 45kW, the simplified method given in paragraph $ should be used. Pipe Loading Outline of Method 1 Approximate pipe sizes are chosen to meet the room loads. 2. Pipe heat losses ere calculated, a. ‘The sums of pipe heat losses and room loads are totalled to give the system heat load. 4 The water quantity circulated in the first section of pipework is calculated by dividing the system heat load by the product [Specific heat capacity x temperature drop selected for the system]. © 11 SNNOA N3avH ©)TM 9.2.11 page 3 a) HEATING PIPE SIZING Nov 72 3.1 Outline of Method (continued) 5 The temperature changes along the pipes to the first pair of branches are each calculated by dividing the pipe heat loss by the product {Specific heat capacity x flow rate} 6 The flow rate beyond the branch is calculated by dividing the heat load beyond the branch by [Specific heat capacity x temperature difference derived from 5), 7 Steps § and 6 are repeated for each section of pipework until the flow rates in all have been found. 3.2 Pipe Heat Emissions 3.21 Bare pipes Table 1 may be used for bare steel or copper pipes, running horizontal or vertical. a 8 3 Pipe size mm | Heat Emission W/m for Water-Air temp diff *C Zz Steel Copper [7 25 50 73 [100 TSO 3 15 15 25 55 90 fe 20 22 30 65 110 2 25 28 35 15 130 $ 3238 40 95 160 40 42 45 110 180 @ 50 84 55 | 130 | ato 6587 70 160 | 260 8076 80 180 | 300 100108 100 | 230 | 370 125133 110 | 270 | 450 150159 130 310 | 520 200 250 300 TABLE 3TM 9.2.11 page 4 HEATING PIPE SIZING Nov 72 12.2 Pipes insulated to TM 13. 1. 11 Table 2 may be used for insulated steel or copper pipes, running horizontal or vertical. Pipe size mm Heat Emission W/m_for Water-Air temp diff °C Steel Coppfres pS [i [ies | Ta] 7 14 al 32 39 47 TABLE 2 3.3 Normal 2 -pipe Layouts 3.31 Use of pipe loading sheet (fold out after page 7) | Draw a diagram of the system. Number each pipe length, working from the boller and numbering flows and returns individually and consecutively. Enter the pipe reference numbers in Col 2 of the sheet, and the measured lengths in Col 3. 3 Mark the net heat loads on the diagram, These are the required (oom) heat inputs, not allowing for lost pipe emission, 4 Calculate the approximate heat load carried by each pipe by summing the net heat loads from the diagram. Enter these in col 4,@ H® DEN pic TM 9.2.11 page 5 HEATING PIPE SIZING Jun 83 rev 3 ‘Use of Pipe Loading Sheet (continued) Calculate the approximate flow rate for each pipe by dividing the approximate heat load (Col 4) by the product [Specific heat capacity x system temperature drop]. Enter in Col 5. Choose the design value of pressure drop/init length for the index circuit. The economic value is governed by various factors such as size and cost of pipework and insulation, pump power and cost of electricity. For heating systems within buildings, the economic design value is about 300 Pa/m and where problems of regulation are unlikely to arise, this value can be used as the mean for the index circuit. In selecting pipe sizes, the value should not exceed 500 Pa/m in the index circuit, nor should the water velocity exceed 1.5 m/s in index or branch circuits. For mains 65mm and above the maximum velocity may be increased to 3m/s. The economic value for extensive district heating mains may differ, and should preferably be calculated for the specific conditions ; refer to Haden Central Engineering. Where there is a large number of parallel circuits, the adoption of the economic value of pressure drop/unit length may lead to high values of excess pressure at branches, particularly at those close to the pump. Up to 50 kPa these pressures can be absorbed by the use of appropriate regulating valves (see TM 11.215 and TM 11,2.24) without noise problems, Otherwise consider inserting calculated lengths of small-bore tube (with a velocity limit of 1.5 mvs). With values above 50 kPa consider rearranging circuits to reduce the excess pressure. If the values remain above 50 kPa then a lower pressure drop should be used for the index circuit. ‘This will minimise the pressure difference across branch connections and thus assist in successful regulation at the commissioning stage. If it can be seen that, in any case, large pressures will have to be absorbed by regulating valves, a reversed return system should be considered. On large systems and district heating schemes with automatic control by throttling valve, consideration must be given to automatic pressure-differential control ; refer to Haden Central Engineering. With the selected values of pressure drop and velocity, use Col 5 with CIBS Guide 1977, Section C4 to determine pipe sizes. Enter in Col 6. From Tables 1 and 2 in paragraph 3.2, determine the pipe heat emission rate. Enter these in Col 7 for Useful Emission (heat emitted in the heated space) or Col 8 for Lost Emission (heat emitted in non-heated spaces). Calculate the design pipe emission from each pipe (Col 7 or 4 x Col 3) and enter in Col 9 or 10. Calculate the design heat load for each pipe by adding the sum of the lost pipe emissions and the net heat loads progressively from the ends of the system. Include the emissions from both flow and return pipes. Enter in Col 11.TM 9.2, HEATING PIPE, Nov 72 3. 3 IL rt Use of Pipe Loading Sheet (continued) 10 ul 12 13 14 15 16 Enter the design temperature difference for the first pair of flow and return pipes in the system in Col 12. Calculate the design flow rate for the first two pipes in the system by dividing the heat load (Col 11) by the product [Specific heat capacity x initial temperature difference (Col 12)] . Enter the result in Col 13. Calculate the temperature drop along each of the first two pipes of the system by dividing the pipe emission (Col 9 or 10) by the product {Specific heat capacity x flow rate (col 13) } ; enter in col 14 For the flow pipe, deduct the temperature drop (Col 14) from the — previous temperature (Col 15) to give the next temperature. For the return pipe, add the temperature drop (Col 14) to the previous temperature (Col 15) to give the next temperature, Enter these in Col 16; this now contains the actual temperatures at the ends of the first two pipes in the system. Enter the difference between these temperatures in Col 17. ‘This temperature difference is transferred to Col 12 as it is the initial temperature difference for the next section of the system, ‘The next pair of pipes can now be loaded. Divide the heat load (Col 11) by the product [Specific heat capacity x initial temperature difference (Col 12)] to give the design flow rate; enter in Col 13. Repeat steps 12-15 until the system is completed. od NagVvH ©© HADEN YOUNG LTD ( TM 9.2. 11 page 7 HEATING PIPE SIZING Nov 72, 3.3.2 Worked example The two-pipe system to be loaded is shown in Pig 1 below. ‘The working of the example is shown on the Pipe Loading Sheet which folds out from this page. Branch A : 3 radiators at 2 500 W Fig1 2-pipe Example System : Pipe Loading Method We Branch B: 2 radiators * at 3 000 W Branch C : 3 radiators at 2 500 W Temperature data : Flow, 85°C Return 65°C Room 20°CYOUNG LTD. PIPE LOADING SHEET joo... TR aver LTHW [orn 2° PIPE | svarew rrow ramp @5.c¢ | mum REFERENCE APPROXIMATE 1 ada 4 ‘ ’ ‘ s | oo " crest | Pine | Length | Wet neat tout | Flow rate pipe emission rate | Pipe omission | Heat Lard w els wim w w o veer | tot | Usetat {tose ‘Sone apxae Bx | Bi) xfer we) NO). Gl 989 + 0!jn EM 9.2. HEATING PIPE SIZING 85.6 REDUAN TEMP ee OB oon 8 rene prop A. 20 DESIGN mr 0 n a “ 6 7 18 Het tod | tatal emp sit | flowrate | Temp drop | Previustonp | Next cemp | Final comp ait | Nove w Powe ret els *c *e *c Flow = return “ o De -Ttgpee) < Er a Sphecapx (i) | Sphecapx [D) ome eee ane 235\2 | zo __ hae? alan Woe | 19-4605] 0-183 | 0-197 19: 086 19. 086 0:079 0-135, «543 | 84.408 a op 0185 | 65.457| 65.592 He -3tdo | ia-8ie | 0.040 | 0.835 [84.408 | ga. 0-535_| 65-592 | 3.030 18. 816. 0.039 | 0.275 | 84.408 0-275 | 66.592 | = were Wea" Sores [49 « 10) ia a 9 tel 421 x 10 no 425 x10) 150 429 10)© HADEN YOUNG LTD TM 9.2.11 page 9 HEATING PIPE SIZING Nov 72 3 Pipe Loading (continued) 3.4 Reversed Return Layouts ‘This procedure uses the same Pipe Loading Sheet as for normal 2-pipe layouts; thus a system containing both normal and reversed return sections can be loaded on the same sheet. 3.4.1 Use of Pipe Loading Sheet (fold out after page 13) | Draw a diagram of the system and number each pipe length. It will be seen from the worked example in 3.4. 2 that the most convenient order for numbering is a) the flow, then the return, of the two-pipe section b) along the flow towards, but not including, the connection to the last heater ©) back along the return towards, but not including, the connection to the first heater d) the connections to the heaters. 2 Enter the pipe reference numbers in Col 2 of the Sheet, and the measured lengths in Col 3. 3 Mark the net heat loads on the diagram. These are the required (room) heat inputs, not allowing for lost pipe emission. 4 Calculate the approximate heat load carried by each pipe by summing the net heat loads from the diagram. Enter these in Col 4. 5 Calculate the approximate flow rate for each pipe by dividing the approximate heat load (Col 4) by the product [Specific heat capacity x system temperature drop J, Enter in Col 5. 6 Choose the design value of pressure drop/unit length; generally, a pressure drop of about 300 N/m* per metre should be used, with a maximum of 500 N/m? per metre and @ maximum velocity of 2. 5 m/s. Use Col 5 and IHVE Guide 1970, Section C4 to determine pipe sizes. Enter in Col 6. 7 From Tables 1 and 2 in para 3, 2, determine the pipe heat emission rate. Enter these in Col 7 for Useful Emission (heat emitted in the heated space) or Col 8 for Lost Emission (heat emitted in non-heated spaces).TM 9.2.11 HEATING PIPE SIZING Nov 72 3.4.1 page 10 Use of Pipe Loading Sheet (continued) 8 10 13 14 15 Calculate the design pipe emission from each pipe (Col 7 or 8 x Col 3) and enter in Col 9 or 10. Sum the net heat loads and the lost pipe emissions for all the system, to give the design total system load. Enter this, as the design heat load for the first flow and return pipes in the system, in Col 11. Enter the design temperature difference for the first pair of flow and return pipes in the system in Col 12. Calculate the design flow rate for the first two pipes in the system by dividing the heat load (Col 11) by the product [Specific heat capacity x initial temperature difference (Col 12)], Enter the result in Col 13. Calculate the temperature drop along each of the first two pipes of the system by dividing the pipe emission (Col 9 or 10) by the product { Specific heat capacity x flow rate (Col 13) }; enter in col 14. For the flow pipe, deduct the temperature drop (Col 14) from the previous temperature (Col 15) to give the next temperature. For the return pipe, add the temperature drop (Col 14) to the previous temperature (Col 15) to give the next temperature. Enter these in Col 16 Col 16 now contains the temperatures at the beginning of the next two pipes, which are the first two ‘reversed return’ pipes; because of this, the normal 2-pipe method cannot be used. An approximate method is adopted. Repeat steps 12 and 13 for the succeeding pipes in the flow and return runs, but divide the pipe emission (Col 9 or 10) by the product {Specific heat capacity x approximate flow rate (Col 5)} to derive the temperature drops to be entered into Col 14. Do not include the flow connection to the last heater or the return connection from the first heater, ‘The temperatures in Col 16 are those at each tee along the flow and return runs; from them, calculate and enter in Col 12 the temperature difference across each circuit to a heater. LT ENNOA NIGH© HADEN YOUNG LTD 3.4.1 TM 9.2. 11 page 11 HEATING PIPE SIZING Nov 72 Use of Pipe Loading Sheet (continued) 7 18 Sum, for each circuit to a heater, the lost pipe emissions from flow and return (Col 10) and net heat load (Col 4) to give the design heat load; enter in Col 11. For each circuit to a heater, divide the design heat load (Col 11) by the product [Specific heat capacity x temperature difference across the circuit (Col 12)] to give the design flow rate, Enter in Col 13. Sum the heater circuit design flow rates (Col 13) progressively to give the design flow rates for the main flow and return runs; these may be entered in Col 18, and will be used in the pipe sizing procedure.mp} TM 9.2.11 page 12 Sig: HEATING PIPE SIZING Che Nov 72 or 3.4.2 Worked example ‘The reversed return system to be loaded is shown in Fig 2 opposite. ‘The working of the cxample is shown on the Pipe Loading Sheet which folds out from the next page. 11 ONNOA NaavH @ (rp "9 HADEN YOUNG LTD T™9.2.11 page 13 HEATING PIPE SIZING Nov 72 Fig. 2 [Pinenstone_in metresPIPE LOADING SHEET HADEN YOUNG LTD. EVEL cD wwer LHW estou EUR ersreu towne BB tc TEFERENCE “APPROXIMATE to 5 ‘ ry .etelwl] o crest | on | on ee epee ee aca eneee eect een ene ete eh na win w w ae @ netu! Sp he capa Bs | x0] rf a) na 4“| joo TM 9.2, 1. HEATING PIPE, SIZING [pare | 85 wren @5__ ve [re oor Ae 20... ce _ | sicer nn esion fe T uw 2 B 4 6 6 7 8 vit tod | tana tomp ott | sloweate | temp drop | erevourvanp | Nese coup | fiat camp a | Moves w Pow =satrn wef “c *e flow return | Flew “ oD Oe 9 “ rahe 2) xfiay- te) Bian B+ om | tye | {14.298 | __20 2.170. o.t4 | i {4 298 1 20 0170. 18 4 1.00_ \ 0-30 | 83 a pee Ee | 2:t0 J _ 9.30 {pss 18:28 | 0-045 ae 9.045 fa 17:28 | 9.04: - | 0.042 | sou | 17-28. 0042 4 0042. 3089; 17-38 | 0-042 tt 9-042, | | 79 42x 10) 45 x 10 404 10© HADEN YOUNG LTD TM 9, 2.11 page 15 HEATING PIPE SIZING Nov 72 3.5 Approximate Method 3.5.1 Where the total load is over 45 kilowatts and the flow increase on the last branch is 7% or less, an approximate method of loading may be used. 3.5.2 To estimate the percentage flow increase: | Load the system in kg/s using the temperature drop at the boiler for every branch. 2 From Table 3 (for bare pipe) or Table 4 (for insulated pipe}, calculate the temperature at each branch off the flow, working out from the boiler. 3 Calculate Where t, = boiler flow temp tyets tz = boiler return temp Tea ¥ 100% ty = temp at last branch tte off flow main If the calculated value is 7% or less, ‘increase the loads used in 3.5.2 step 1 as follows: Approximate design flow rate = Initial flow rate x Where 1, is the temp at the branch off flowPMO. 211 page 16 HEATING PIPE SIZING Nov 72 3.5 Approximate method (continued) G41 ONNDA NiavH © \ ‘Temperature drop °C/m for alternative pressure drops N/m? per metre HORIZONTAL VERTICAL 100 240 400 100 240 [400 N/m? per metre 0. 260 0.200 0.310 0.200 0.140 0.140 0, 100 0.170 0.110 0. 081 6. 088 0. 067 0.120 0. 072 0.055 0. 049 0. 038 0.065 0. O41 0.032 0. 036 0. 038 0. 050 0.081 0,024 0, 023 0. 18 0.033 0.020 0. 016 0, 010, 0. 010 0,020 0.010 0.010 0. 010 0.010 0.020 0.010 0,010 0.010 0.010 0.010 0.010 0.010 — TABLE 3 BARE PIPES AT 90 °C Pipe ‘Temperature drop °C/m for alternative pressure drops N/m? permetre PIPES AT 90 °C PIPES AT 150 °C mm| 100 250 400 100 250 400 N/m® per metre 15] 0,100 | 0.000 0. 087 0, 180 0. 120 0. 087 20] 0. 051 | 0.031 0. 024 0.077 0. 048 0,037 t 25| 0.029 | 0. 018 0, 014 0. 048 0.030 0, 023 32} 0.013 | 0. 008 6. 006 0.022 0. 014 Qoi 40]0.010 | 0.006 ©. 005 0. 016 6, 010 0, 008 50] 0. 005 | 0. oF 0.003 0.010 0, 006 0. 005 65 Jo. 004 | 0.002 0. 002 0. 006 0.004 0. 008 80 jo. 003 | 0. 002 0. 001 0.003 0. 002 0. 002 100 | 0.001 | 0.001 0.001 0. 002 0. 001 0. oo TABLE 4 PIPES INSULATED AS TM 13.1.11@ HADEN pic 1M 9.2.11 page 17 HEATING PIPE SIZING Jun 83 rev 2 Pipe Sizing Explanation of Method for 2 -pipe Systems ! L 2. 3. Bisa tee tulsand rite eaveny tertid cenneetia ‘The index circuit ie that which appears to offer the greatest resistance to the flow of water, is identified by inspection. It will normally be the circuit with the longest run of pipe. The pipe length identities, and flow rates (obtained from the Pipe Loading Sheet) are tabulated from the far end of the system. The pipe size appropriate to the flow rate and the pressure drop rate*used in Pipe Loading (see 3. 3. 1 step 6) is found from IHVE Guide 1970 Section C4; these tables also give the actual pressure drop rate for the selected pipe size at the flow rate, and the Equivalent Length value (EL) used to find the resistance of fittings. ‘The number of pipe fittings is totalled, without distinguishing between bends, elbows, tees, reducing sockets etc, and a mean value of k = 0.8 is applied to them in the calculation : Fittings equivalent length = Number of fittings x EL x k Circuit valves, radiators, boilers, and all other resistances must be counted separately, and the k values in Table C4, 40 in the IHVE Guide or Manufacturer’s data for head loss, be applied. Pressure loss for radiator valves is taken from the data in TM 11.2.43. ‘The equivalent length of pipe from fittings and from all other resistances is added to the measured length to give the total effective length of each section of the index circuit ; these are multiplied by the appropriate pressure drop rates, and summed to give the total resistance of the index circuit. ‘The calculated index resistance should be increased by a margin (see TM 10. 5.11 para 7.4) to give the operating head of the pump. The calculated system flow rate is also increased by a margin (sce TM 10, 5.11 para 7.4). The available pressure at each branch offtake is noted from the tabulation, and the approximate effective length assessed, as in steps 4 and 5. The pressure drop rate appropriate to the branch is found by dividing the available pressure at the ofitake by the effective length. Steps 3, 4 and 5 are then repeated using this pressure drop rate. ‘The pressure absorbed by the fully-open radiator valve (used as a shut-off valve) is obtained from the charts in TM 11.2.43. Any pressure remaining is then absorbed by a radiator valve positioned at the appropriate setting also obtained using the charts in TM 11.2.43. ‘The veterene es given, and the data used for the worked example, are from the 1970 edition of the IHVE Gulde, The Table numbering, and some of the coefficients and factors, are different in the 1977 edition of oh, ale tet Le Lees thar itaretse ote ne tla clade be tenis suse tants as fo testded tea aed Buircis a dar ay the sateTM 9.2.11 page 18 i HEATING PIPE SIZING Sep 78 rev 1 4.2 Corrections to IHVE Guide Main Tables 4.2.1 For water at 150°C In the most used part of Table C4. 5 in the IHVE Guide, the multiplying factors are so near unity as to make it unnecessary to apply them, The main tables can therefore be used unchanged for water temperatures between 75°C and 150°C, 4.2.2 For medium~ or heavy grade tube ‘Tables C4. 8 and C4. 9 refer respectively to heavy and to medium grade tube ; the appropriate table should be used, 4,3 Use of Pipe Sizing Sheet (fold out after page 21) 1, Enter in Col 19 the circuit identification "Index! , in Col 20 the paired pipe numbers starting from the far end of the system, and in Col 21 the required flow rates against each pair of pipes. Ee 2, Enter in Col 23 the pressure drop rate used in Pipe Loading (see 3, 3, 1 step 6). 3, In Col 24 onter the pipe size, obtained from the appropriate Table in the IHVE Guide, which will carry the flow in Col 21 at a pressure drop rate as close as possible to that in Col 23, At the same time, enter in Col 28 the value of KL and in Col 32 the actual pressure drop rate for the pipe size chosen and the flow rate in Col 21. 4, Enter in Col 25 the pipe length sealed from drawings. 5. Count the number of pipe fittings ; note the total and, separately, valves and other unit resistances, in Col 26. 6, Multiply the number of pipe fittings by 0,8, and the other unit resistances respectively by their k values from Table C4. 40 of the IHVE Guide, Sum the total and enter in Col 27. 7. Multiply Col 27 by Col 28 to give the equivalent length of all fittings and unit resistances ; enter in Col 29. 8, Add Col 29 to Col 25 to give the total effective length ; enter in Col 30, 9. From Col 30 and Col 32 calculate the resistance of the section, and enter in Col 83. 10, For each radiator valve in turn enter in Col 33 the resistance found from the charts in TM 11, 2, 43, Note ; In the Index Circuit both radiator vaives will be in the fully open position. In the other branch clreults one radiator valve will be in the fully open position and the other will be positfoned at the appropriate setting found from the charts in TM 21.2.43 to absorb any excess pressure in the eireuit. ad N3gvH @@ HADEN YOUNG LTD 4.3 TM 9.2.13 page 19 BEATING PIPE 'SIZING Sep 78 rev i Use of Pipe Sizing Sheet (continued) i, 12. 13. 14, 15. 16. 17. The cumuiaiv: vetals in Col 33 are entered in Col 34; the final total for the wicie of the index circuit is transferred to the tabulation 'Puinp Deiails' at the foot of the sheet (item 41). For each Branch Cireu:t in turn enter in Col 19 the branch cireuit identification “Branch. . . . .. "; nm Col 20 the paired pipe numbers starting from the near the end of the branch ; and in Col 21 the required flow rates for each pair of pipes. ‘Then repeat step 4, ‘Transfer the appropriate value from Col 34 to Col 22. ‘The total pressure available will be the pump pressure less the pressure Joss in the index circuit up to the offtake. By comparison with the index circuit, assess approximately the equivalent length of all fittings and unit resistances in the run or the branca, Add this to the scaled length (Col 25) and divide the sum into Col 22 to give an approximate pressure drop rate; enter is Coi 23. Repeat steps 3, 5, 6, 7, 8, 9,10. ‘The cumulative totals in Col 33 are entered in Coi 34, including the fully open shut-off radiator valve, The difference Col 22 « Cel 34 is entered in Col 33 and this remaming pressure is absorbed by the second radiator valve ; the appropriate setung ig entered in Coi 36, In the case where the branch circuit has a. .. rge sumber of radiators an alternative procedure should : use 1, insteca of using the radiator valves to obtain a circuit balance «1s more appropriate to use the radiator valves to obtain 4 valance setween all the radiators in the circuit and then use a pair of arcu isolating valves one of which 1g us 2 io balance tae branclTM9.2.11 page 20 HEATING PIPH S!2ING Sep 78 sev 1 Worked Example ‘The system to be si and is shown in Fig 3 opposite. on the Pipe Sizing Sheet which 44 ni ig that used in the Pipe Loading example, e working of the example is shown is out from the next page, O49 eaInar amavay (© HADEN YOUNG 1D Pipe Sizing Method TM 9.2.11 page 21 HEATING PIPE. SIZING Sep 78 rev 1 Fig. 3 EXAMPLE SYSTEM [Ei diseneton in otrosHADEN YOUNG LTD PIPE SIZING SHEET ‘SeRMCE. Noe Th He WW. PIPE. DESIGN FLOW TE «[» a 22 nm fu fe % afew» REFERENCE PIPE LOAD & Size EFFECTIVE LENGTH OF TRAVEL FLow Toul [Amp ie EQUIVALENT LENGTH TOTAL LET rent | lite | ATE |e so | ero ae tt Be lave ei mim | [PRIMO vauves, er 59°" | ek. easy Pet] [iNpee Sho 0-034 iSo | 15 | 9 jaw 4F | 2 | od | 3.28 | 12-28 z 0.034 is | - av Gon Eht (ou fee st sent e034 1s | = tv 118 0-069 3/16 ar {ib [05 [0-8] 6-80 she O08 20 {38 GF | 4-8 | o7 13-36) 41-36 3/4 0-183 20 | 1b 26 [be [ot [rie) 112 7 9-280 25 [32 he av qr {te | 1 [teto laifaz | 0-034 | 899 ) 15 | 3 |e SF {8-2 | 0-4 | 328] 6.28 0-034 "a Lis | Ww e034 J 15 | = w ITS, 16 | 3 He Sf |8.2 |0-4 1328] 6-28 15 | = aw 0.034 | js] - tv ¥ Beaver 6 v3 fry 0075 4197 is | 6 SF [32 [O'S [No 74 Is/Ie 0+ 045 3037 is] nr We 4f 18.2 10-4 |3-26| 15-28 sf = ay J - 1S Sv ' Whe | 0-089 | 3057 1s 4g 4e [a2 [og [328] 15-28 wv : Wv | Barns A nin | O-100 | T07 2 | 25 tor |8-0 [0-7 [5-6 | 30-60 2o | - wv Aware. [Wnere A arne Nonieee lor tAlFoe3 occur on lome [Beancy, ITS! Vauves, oneloe wed 1s weer | 7a ladcanvce THe BRAveH; Larner al —BETATES- PECK a7 [eERviCe uraw 740 [FLOW RATE (wom eal 2) 0-280 0 Ia] tam ve ae DESIGN TEMP. AT PUMP 85 se [ft [ RESISTANGE (rom col. 34) BUS Nim —_ ag [sraric PRESSURE AT PUMP 1:80 bar [a2 | RERSENTACE, WP. [a BO x] 20 x|“*| Younes P5130 ATMOS AYSHEET i DESIGN FLOW TEL. 85. ve [teur DROP TH OF TRAVEL PRESSURE DROP TOTAL LENGTH Le (x ED: Bal Per] CuncTatve soction | _ Totals 20, Nimo oars * Nim Totals Po. Nim lpexet EL ea xa ber moto oa [32g | 12:2 325 | 399 399 64: 3 16 it 1 12 [1311 D> g2e| is 28 SPECIFIC VOLUME OF WATER Dos ain We dogo =|") Wore TMIO SAY 43] Temp. °c} 20 1-00 60 \Zes\ | 200 | 125 | 150 sot Kr03)] 106 | 107 | 1-09 Cumulative sont. 9.2M),.WTG. PURE Sizing ..USiNG. MERZ. VARNES... Rac SHEET No REF REMARKS Presse teaining Nim te 5424 Netz StRAn loseo aD A Cigewir PUMP DUTY Flow wm x fx trap t-100) Pressure fi] = (HMengin-t 100 (settng of Reg. Vaive) y 0.35 livers (G00 N/m"@ HADEN YOUNG LTO TM 92 11 page 23 HEATING PIPE SIZING Feb 80 rev | 4.5 One -pipe Systems ‘The one-pipe loops and heater connections are sized using the method set out in'TM 5. 1,21, The remainder of the system being 2-pipe is «i using the method set out in para 3. 4 4.6 Systems with Rooftop Boiler Plant When the boiler plant is located at roof level the smallest pipe sizes will occur at the bottom of the systera, Care must be taken to include adequate flushing facilities, with generously-sized sludge pockets, at the bottom of the system. To reduce the risk of blockage, consideration should be given to 1 increasing the smallest pipe 2 installing pipe strainers 3 chemically cleaning and flushing before final filling. See also TM 9.6.13 Preventing Piping Blockage. Method for a Quick Approximation 1 Assess a percentage addition for pipe losses using Tables 3 and 4 Take the mean pipe size and length of the index circuit. 47 Then Total temperature drop from pipe losses Percentage addition = x 100 System design temperature drop 2 Add twice this percentage to circuits remote from the boiler, nothing to those close to the boiler, and pro-rata in between, 3 Select pipe sizes appropriate to these adjusted loads and the pressure drop rate chosen for the system.TM9.2.11 page 24 HEATING PIPE SIZING Nov 72 5 Simplified Method for Small Radiator Systems This simplified method of pump selection and pipe sizing may be used for radiator systems where the total ioad is less than 45 kW, BL Pump Selection ‘The pump duty flow should be the total heat load increased by a margin of 20% divided by [Specific heat capacity x 20 °C temperature dip 1. The pump pressure should be selected from Table 5, in which the Total effective length of index circuit = Net scaled length x 1. 5 Total effective length Recommended ‘ of index circuit m pump pressure N/m? Less than 30 6 000 - 9 000 30-50 10 000 - 16 000 50+ 150 18 000 = 27 000 TABLE 5 5.2 Pipe Sizing 5.21 Table 6 gives the carrying capacity in W of five pipe sizes for various effective lengths of circuit and the three ranges of pump pressure. Pump pressure N/m? Pipe size mm 000-9 000 [10 000-16 000|18 000-27 o00|| 10 | 15 | 22 | 28 35 Cirenit effective length m Capacity W with 20 °C drop 111 300 |21 100 8 700 |16 100 6 750 |12 550 [36 400 5 150} 9 600 127 900 4 100] 7 750 [22 400 |45 000 3 200 | 6 050117 700 |35 650 2 450 | 4 550/13 300|26 800|(48 200) TABLE 6 ‘The Table can be used to size the index circuit and the branch circuits, in ali cases using the effective length measured from the boiler to the last radiator in the circuit. The nearest pipe size, ap or down, should be selected for the actual pipe heat load 11 SNNOA N3avH ©© HADEN YOUNG LTD TM 9.2.11 page 25 52 5.22 HEATING PIPE SIZING Nov 72 Pipe Sizing (continued) For conventional one-pipe loops (ie not using 3-way valves} the following rules should be observed: 1 The maximum toad on each loop must not require a main larger than 22 mm. So that the temperature of the last radiator is not too low, not more than five radiators should be served from one loop. No single radiator should have an output greater than 4. 5 kW, Radiator connections should in all cases be 15 mm whether the main is 15 or 22 mm. Radiator connections should be as short as possible, and in no case exceed (@) for radiators on the same floor as the main: 2 metres net run excluding equivalent lengths of valves etc (b) for radiators on storey above main: 8 metres net run excluding equivalent lengths of valves etc. Under these conditions it may be assumed that 20% of the water will be diverted through each radiator, with 80% flowing through the main between the radiator connections, The temperature drop in radiators, and the radiator mean temperature and size, can be calculated (as TM 5, 1, 21 Example 1) if necessary,TM 9. 2. If page 26 HEATING PIPE SIZING Nov 72 5. 3 Worked Example Pump selection: Duty = Pi : Scaled 1 Ressure: “Fotal effective length = 6x 1.3 26,500 Wx 1, 20 «10° x 20°C 0.378 kgs 0. 39 litre/s th of index circuit AXF = 56 m + 84m From Table 5: Pump pressure = 18-27 kN/m? Sizing index circuit: From Table 6: Pipe identity Load W Sizing branch circuits: AB, EF 26 500 BC, DE 16 500 CXD 8 000 Identity Scaled length Effective length ABEF ACYDF m 28 40 m 33 60 Pipe BE cYD Size mm 28 22 22 Load W § 000 7 500 Size mm 15 15 NAOA NadvH ©) Gui 21Related Topics TM5.1.11 Selection of flow temperature and temperature drop in LTHW heating groups: TM5.1.12 Flow &and return temperatures, flow rates and heat outputs TM5.1.21 Design of one-pipe radiator heating systems TM9.1.21 Primary and secondary water circuit design TM92.12 Orifice plates for absorbing excess pump pressure in water circuits TM 9.10.11 Company specification: LTHW heating pipawork Post-it Note Tho main TM section and the related topics give basic information only and are not necessarily up to date, so refer also to: CIBSE Guide C: Section C4-Flow of fluids in pipes and ducts