Basic Traininghydronics by Belimo

Belimo Aircontrols, Inc.
(USA)
Basic Hydronic Training
BELIMO Aircontrols
Basic Hydronic Training 1
System Components
BELIMO Aircontrols
Components in a Hydronic System
6 7 1
Source
3
4
1. 2. 3. 4. 5. 6. 7.
Pump Load Control Valve Balancing Valve Source Air Removal System Expansion Unit
Load
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Source Carrier Load

Water, Air, Refrigerant, Electricity
Heating Cooling
Source
Load
Heating Load Cooling Load
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Hydronic Systems
Cooling
43F 40F
Chiller
Heating 245F
45F
Cooling Coil
250F
Boiler
240F
Heating Coil
57F
55F
185F
190F
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Water Systems
Load
Source
Source
Expansion Chamber
Closed System
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Open System
Load
Closed Water Systems

Low Temperature Water (LTW) - Max. 160PSI and max. 250F Medium Temperature Water (MTW) -Max. 160PSI / 250F to 350F High Temperature Water (HTW) -Max. 300 PSI and max. 350F Chilled Water Systems (CWS) - Max. 120 PSI / 40F to 55F (44F or 45F)
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Piping Circuits
Two Pipe System Three Pipe System Four Pipe System Direct and Reverse Return Systems Primary-Secondary System
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Two Pipe System

Main Supply Chilled Water or Heat Water Supply one pipe, Return one pipe Cooling or heating at source Loads must all require cooling or heating coincidentally
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Two Pipe System
Chiller
Boiler
Load
Load
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Load
Two Pipe System
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Three Pipe System
Chiller
Boiler
Load
Load
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Load
Three Pipe System
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Three-Pipe System
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Four Pipe System
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Four Pipe System with One Coil
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Four Pipe System with H&C Coil
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Cost for Four Pipe System

High first cost due to the second water system and the need for either two coils or more costly control valves at each terminal unit. High operating cost due to the two pumps operating, but do provide good flexibility in meeting varying loads.
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Advantages of Four Pipe Systems

All year availability of heating and cooling with individual zone temperature control
Chilled and hot water are typically only simultaneously supplied during the Spring and Fall seasons
Elimination of zoning cost and complexity Simpler changeover decisions The lowest and quietest fan speed is adequate most of the time.
BELIMO Aircontrols
Piping - Direct Return Piping

Coil #4 0 - 100 gpm
Coil #3 0 - 100 gpm
Coil #2 0 - 100 gpm
Coil #1 0 - 100 gpm
Source
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Piping - Reverse Return Piping

Coil #4 0 - 100 gpm
Coil #3 0 - 100 gpm
Coil #2 0 - 100 gpm
Coil #1 0 - 100 gpm
Source
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Primary Secondary System
Source
Source
Source
Load
Load
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Load
Pipe Design
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Bernoullis Law
pstat pdyn const.
The Bernoullis law is stating the principle of energy conservation. The sum of the two energies represented by static pressure and dynamic pressure is constant between two points in the pipe, assuming no energy exchange with the exterior or transformation of energy into heat by friction between these two points.
BELIMO Aircontrols
Bernoullis Law
pdyn1
ptotal1 pstatic1
pdyn2
ptotal2
pstatic2
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Z1
V12 2g
P 1
1
Z2
V22 2g
P2
2
hL
V2 P2
hL
V1 P1
Z2
1
Z1
BELIMO Aircontrols
Pipe Sizing and Pressure Drop Equations

h L f D V2 2g
Darcy-Weisbach Equation
h pressure drop, in ft f friction factor, dimensionl ess (from Moody ) L Length of pipe, ft D Internal Diameter of pipe, in V Fluid average velocity, ft/sec g gravitatio nal constan, 32.2 ft/sec 2
BELIMO Aircontrols
Sizing a Piping System Pipe Friction Loss

Suggested head loss in range from 1 to 4ft per 100ft - 1997 ASHRAE Handbook-Fundamentals Max. 4 ft/sec velocity in pipe 2 Suggested 4 ft/sec velocity in pipes larger than 2
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Simplified Method
D S Q 0 .4
D = Pipe Diameter Q = Flow Rate, GPM S = Pipe Sizing Constant - S= 0.44, assuming 4 ft head drop/100ft - S = 0.5 assuming 2 ft head drop/ 100ft
BELIMO Aircontrols
Examples
Load: 100GPM D = SQ0.4 = 0.44 x 1000.4 = 2.78 3
Load: 200GPM D = SQ0.4 = 0.44 x 2000.4 = 3.66 4

Load: 300GPM D = SQ0.4 = 0.44 x 3000.4 = 4.31 4 Load: 400GPM D = SQ0.4 = 0.44 x 4000.4 = 4.83 5
BELIMO Aircontrols
Head Loss Calculation

Pipes (Friction Loss for Water in Commercial Steel Pipe (Schedule 40) Strainers, Fitting, Elbows, Reduction, etc Valves, Balancing Valves (Valve - Manufacturer)
Head loss Load (Coil, etc.)

Head loss Source (Chiller, etc.)
=Total Head Loss

BELIMO Aircontrols
Head Loss in Pipes

Head Loss 2.5ft
Pipes (Friction Loss for Water in Commercial Steel Pipe (Schedule 40)
100GPM
Flow Rate
hspec =ft/100ft pipe Total h=L x hspec /100
BELIMO Aircontrols
Fittings
h V2 k 2g
h = head loss in feet of water k = resistance coefficient for valve or fitting V2/2g = velocity head, ft based on flow gpm in connect pipe (example Figure 2 15 for 2 in) V = fluid velocity, ft/sec g = 32.2 ft/sec2, gravitational constant
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BELIMO Aircontrols
Which pump do we choose?

Total Pipe length = 300 ft BTU/HR = 500,000 BTU/HR T = 10F GPM = ?
GPM
BTUH T 500
GPM
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BTUH T 500
500000 100GPM 10x500

Chiller
Coil
What is the pipe size?

Required Flow: 100GPM Pipe Diameter: ?
D S Q 0 .4
D = SQ0.4 = 0.44 x 1000.4 = 2.78 3
D = Pipe Diameter Q = Flow Rate, GPM S = Pipe Sizing Constant S= 0.44, assuming 4 ft head loss/100ft S = 0.5 assuming 2 ft head loss/ 100ft
BELIMO Aircontrols
Head loss elbows?

Pipe: 3, Steel Pipe, screwed Head loss of total elbows?
V2 k 2g
42 0.8 2 32.2 0.2 ft
4 Elbow 0.8ft
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Chiller
Coil
Head loss pipe?

Pipe: 3, Steel Pipe, screwed Total Pipe length = 300 ft
Pipes (Friction Loss for Water in Commercial Steel Pipe (Schedule 40) Figure 2-14 Friction Loss - Water 2.5 ft/100ft
h = 300 x 2.5 /100 = 7.5ft

BELIMO Aircontrols
Chiller
Coil
Total head loss?

1 Chiller 9 ft (4PSI, Info Manuf.) 1 Cooling Coil 9 ft (4PSI, Info Manuf.) 1 Control Valve 9 ft (4PSI) 1 Balance Valve 3 ft (1PSI) 4 Elbows each 0.2 ft 0.8 ft 1 Pipe System 7.5 ft
Total Head Loss of 38.3ft at 100GPM

BELIMO Aircontrols
Chiller
Coil
System Curve
80 60
Head (ft)
40
System Point at design load
20
10
Head Loss of 38.3 at 100GPM

0
20 40 60
80
100
120
140
160
180
200
Flow GPM
BELIMO Aircontrols
Pumps in HVAC
BELIMO Aircontrols
Pumps in HVAC
Pumps
Dynamic
Displacement
Centrifugal
Special Effect
Reciprocating
Rotary Pumps
Volute Type
Axial Flow Type
Single Suction
Double Suction
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Outlet Flow
Impeller
Inlet Flow
Blade
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Pump Curve
Pump Head
Pump Characteristic
Chiller
Coil
Operating Point
System Head
V
100%
Volume
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Pump Curve (Steep)
Pump Characteristic
Chiller
Coil
Operating Point
100%
Volume
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Pump Curve (Flat)
Pump Characteristic
Chiller
Coil
Operating Point
25%
V
100%
Volume
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Operating Point
Pump Head Capacity Curve
p
Chiller
Coil
Operating Point
Load 100% Flow
100%
System Head Curve
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System Curves for a Pump Type

80 60
7.0 6.5 6.0 5.5 5.0
70%65% 60% 55%
Head (ft)
40
20
10
20
40
60
80
100
120
140
160
180
200
Flow GPM
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Motor Horsepower
Minimum Flow of Pump

Depends on pump construction and energy generated by pump Not enough flow could result in overheating and cavitation Some low power pumps can operate at zero flow Installation of bypass circuit
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Valves in HVAC
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What Control Characteristic is Preferred?

100 90 80
Heat Output (%)
70 60 50 40 30 20 10
Heat Output
10
20
30
40
50
60
70
80
90
100
Control Signal (%)
BELIMO Aircontrols
What are the Coil Characteristics?

100
Characteristic of a coil Heat Output (%)
90 80 70 60 50 40 30 20 10
Heat Output
10
20
30
40
50
60
70
80
90
100
Valve Opening (%)
BELIMO Aircontrols
What are the Valve Characteristics?

100
Flow, Heat Output (%)
Characteristic of a Coil
90 80 70 60 50 40 30 20 10
Heat Output
Characteristic of Control Valve
10
20
30
40
50
60
70
80
90
100
Signal (%)
BELIMO Aircontrols
Valve Characteristics Modified Equal Percentage

100 Lift 90 80 Theoretical Flow Corrected Flow
100 90
100 80 64
100 80 64
Flow (%)
70 60 50 40 30 20
80
70
60 50 40
51
41 33 26 21 17 13.4 10.7
51
41 33 26 19.5 13 6.5 0
Equal % Linear Curve

10 20 30 40 50 60 70 80 90
30 20 10 0 100
10.7
10
Valve Opening (Signal) (%)

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Valve Authority
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Authority of Control Valves with Variable Flow Through the Coil

Authority of two way control valves Authority of three way control valves
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3-way Control Valve

4 4 12
20 psi Const
pv100
pv100 pFlowVariable
pv100 pv 0
A
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4 8
0.5
3-way Control Valve

4
A
12
20 psi Const
pv100
pv100 pFlowVariable
pv100 pv 0
A
BELIMO Aircontrols
4 8
0.5
3-way Control Valve

41 50% 01
20 psi Const
45
1214
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Valve Authority - Flow 100%

Coil
P Terminal
P Terminal =const
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P Valve

Coil
P Terminal
P Terminal =const
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P Valve

Coil
P Terminal
P Terminal =const
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P Valve
2-way Control Valve

4 4
12
20 psi VFD
pv100
pv100 pFlowVariable
pv100 pv 0
A
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4 20
0.2
2-way Control Valve

41
416 123
50%
20 psi VFD
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Coil
P Terminal
P Valve
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Coil
P Terminal
P Valve
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Coil
P Terminal
P Terminal =const
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P Valve
Sizing Rules
Authority = 0.4 to 0.5

Min. pvalve = 0.25 p pumphead
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Authority Distortion of Linear Flow Characteristics

100 90 80 0.1 0.2 0.4 0.6 0.8 1 40 30 20 10
Flow (%)
70 60 50
10
20
30
40
50
60
70
80
90
100
Valve Opening (%)

BELIMO Aircontrols
Authority Distortion of Equal Percentage Flow Characteristics

100 90 80 70
Flow (%)
60 50 40 30 20 10
0.1
0.2
0.4 0.6 0.8 1
10
20
30
40
50
60
70
80
90
100
Valve Opening (%)

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Counter-Flow
Cross-Flow
Parallel-Flow
Counter-flow, cross-flow or parallel-flow heat exchangers are used depending on the application. They have different efficiencies.
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Constant or Variable Flow

e.g. air
Regardless of valve position, the full water flow is always circulating through the heat exchanger => Temperature control
Depending of valve position, 0..100% of the water flow circulates through the heat exchanger
=> Flow control
BELIMO Aircontrols
Constant or Variable Flow

Prevention of freezing Large outside flow? Dehumidification
yes
no
no
yes
no
yes
Are different temperature levels in coil acceptable?
no
Temperature control constant Flow Variable temperature
BELIMO Aircontrols
yes
yes
Flow Control Constant Temperature Variable Flow

Diverting Circuit with Mixing Valve

pFV
Coil
var var
var
pV100
100%
100%
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Diverting Circuit with Diverting Valve

pFV
Coil
var var var
pV100
100%
100%
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Throttling Circuit
pFV
Coil
var var
pV100
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Mixing Circuit with Mixing Valve Coil

100% p v100 var 100%
var
var
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Heat Exchanger Characteristics

100 90 80 0.05 0.15 0.25 0.4 0.6 0.8 1 1.5 2 3
Energy (%)
70 60 50 40 30 20 10
Application Pre Heating Coil Heating Coil Cooling Coil Radiators Converters
a-Value 0.25 to 0.4 0.15 to 0.4 0.25 to 0.5 0.5 to 0.65 0.5 3.0
10
20
30
40
50
60
70
80
90
100
Flow (%)
BELIMO Aircontrols

100
90 80
Variable Flow
Energy (%)
70 60 50 40 30 20 10
Constant Flow
10
20
30
40
50
60
70
80
90
100
Flow (%)
BELIMO Aircontrols

100
90 80
T = 10F T = 30F
Energy (%)
70 60 50 40 30 20 10
10
20
30
40
50
60
70
80
90
100
Flow (%)
BELIMO Aircontrols

100
90 80
Heating Coil Cooling Coil
Energy (%)
70 60 50 40 30 20 10
10
20
30
40
50
60
70
80
90
100
Flow (%)
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Influencing Factors
Valve with Hydraulics Heat Exchanger
Base Valve Characteristic
Hydraulic System
System Valve Coil Characteristic Characteristic
Resulting Characteristic
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Conventional Sizing Methods
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Application
Pressure Differential Sensor 10 psi p=2 psi
Coil #4 0 - 100 gpm

p=4 psi Coil #3 0 - 100 gpm p=12 psi p=4 psi Coil #2 0 - 100 gpm p=22 psi p=4 psi Coil #1 0 - 100 gpm p=32 psi p=4 psi
10 psi
p =4 psi
20 psi
20 psi
p =4 psi
30 psi
30 psi
p=4 psi
40 psi
p=4 psi
40 psi
Chiller VFD-Pump
BELIMO Aircontrols
Application
Authority
A=4/10=0.4
Flow/Heat output %
Coil #4 0 - 100 gpm

p=4 psi Coil #3 0 - 100 gpm p=12 psi p=4 psi Coil #2 0 - 100 gpm p=22 psi p=4 psi Coil #1 0 - 100 gpm p=32 psi p=4 psi
p =4 psi
20 psi
p =4 psi
A=4/20=0.2
30 psi
p=4 psi
A=4/30=0.14
40 psi
p=4 psi
A=4/40=0.1
Signal
Chiller VFD-Pump
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Shift to Variable Supply with VFD-Pumps and Two-way Valves 4 4 12
20 psi
Const
4
20 psi
12
VFD
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Authority Method
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Application
Coil #1 0 - 100 gpm

p=4 psi Coil #2 0 - 100 gpm
Flow/Heatoutput
p =4 psi
A=0.5
20 psi
p=6 psi
p =10psi
A=0.5 A=0.5
30 psi p=11 psi
p=15 psi
40 psi p=16 psi
p=4 psi
p=20 psi
A=0.5
Signal
Chiller VFD-Pump
BELIMO Aircontrols
Current Concepts for Valve Sizing

Exact calculation f( p and V)
Correct sized components Generally less expensive components, like valves Complex procedures for all involved More detailed information is required Consideration of diversity factors No feedback of sized devices from suppliers
Rule: pvalve = pCoil
Rule: pvalve= 3 5 psi

BELIMO Aircontrols
Very simple rule Used by all involved in the project Good base for price comparison Oversized valves overpriced valves Bad authority Hunting Instable control loops
Additional Valve Sizing Considerations

Two-way valves: For the close-off pressure the pump head needs to be considered. Three-way valves: Pressure difference valve
For the selection of the valve bodies it is necessary to consider elevation of system, pump pressure and fill pressure
BELIMO Aircontrols
Reference Literature
Total Hydronic Balancing Robert Petitjean, Tour & Andersson Hydronic AB HVAC Pump Handbook James B. Rishel, McGraw-Hill ASHRAE Handbooks HVAC Equations, Data, and Rules of Thumb Bell, McGraw-Hill
BELIMO Aircontrols
Thank You
BELIMO Aircontrols

Basic Traininghydronics by Belimo

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Belimo Aircontrols, Inc.

Basic Hydronic Training

Basic Hydronic Training 1

Basic Hydronic Training 2

Components in a Hydronic System

Basic Hydronic Training 3

Source Carrier Load

Heating Load Cooling Load

Basic Hydronic Training 4

Basic Hydronic Training 5

Closed Water Systems

Basic Hydronic Training 7

Basic Hydronic Training 8

Two Pipe System

Basic Hydronic Training 9

Two Pipe System

Basic Hydronic Training 10

Two Pipe System

Basic Hydronic Training 11

Three Pipe System

Basic Hydronic Training 12

Three Pipe System

Basic Hydronic Training 13

Basic Hydronic Training 14

Four Pipe System

Basic Hydronic Training 15

Four Pipe System with One Coil

Basic Hydronic Training 16

Four Pipe System with H&C Coil

Basic Hydronic Training 17

Cost for Four Pipe System

Basic Hydronic Training 18

Advantages of Four Pipe Systems

Basic Hydronic Training 19

Piping - Direct Return Piping

Coil #3 0 - 100 gpm

Coil #2 0 - 100 gpm

Coil #1 0 - 100 gpm

Basic Hydronic Training 20

Piping - Reverse Return Piping

Coil #3 0 - 100 gpm

Coil #2 0 - 100 gpm

Coil #1 0 - 100 gpm

Basic Hydronic Training 21

Primary Secondary System

Basic Hydronic Training 22

Basic Hydronic Training 23

Basic Hydronic Training 24

Basic Hydronic Training 25

Basic Hydronic Training 26

Pipe Sizing and Pressure Drop Equations

Basic Hydronic Training 27

Sizing a Piping System Pipe Friction Loss

Basic Hydronic Training 28

Basic Hydronic Training 29

Load: 200GPM D = SQ0.4 = 0.44 x 2000.4 = 3.66 4

Basic Hydronic Training 30

Head Loss Calculation

Head loss Load (Coil, etc.)

=Total Head Loss

Basic Hydronic Training 31

Head Loss in Pipes

hspec =ft/100ft pipe Total h=L x hspec /100