The document discusses various topics related to hydronic system design including: - Common hydronic system types like primary-secondary and variable flow systems - Key considerations for piping design like pump sizing, pressure drops, and expansion tank placement - Examples of specific system designs for chilled water, boiler water, and complex multi-building systems - Benefits of variable speed pumps for energy efficiency and system controllability

1. Hydronic System Piping Design Presented by: Dan Watkins, LEED AP Bornquist, Inc.

3. Hydronic System Basics SOURCE LOAD In a Hydronic System

4. Hydronic System Basics SOURCE LOAD Source & Load connected by piping

5. Hydronic System Basics SOURCE LOAD Fluid is circulated by a pump

8. Hydronic System Basics Let’s design a simple system together! Boiler 200,000 BTUh AHU Coil 20 GPM Boiler = 5’ TDH AHU = 10’ TDH Piping = ???

9. Hydronic System Basics Let’s design a simple system together! Rule of Thumb… Length x 1.5 to account for elbows and fittings. 2.94’ per 100’ of piping 100’ x 1.5 = 150’ 1.5 x 2.94’ = 4.41’ TDH

10. Hydronic System Basics Let’s design a simple system together! Boiler 200,000 BTUh AHU Coil 20 GPM Boiler = 5’ TDH AHU = 10’ TDH Piping = 4.41’ TDH System Capacity: 20 GPM @ 19.41’

11. Hydronic System Basics

12. Hydronic System Basics GPM 2 GPM 1 HEAD 2 RPM 2 RPM 1 HEAD 1 HP 2 HP 1 RPM 2 RPM 1 RPM 2 RPM 1 HP 2 HP 1 GPM 2 GPM 1 GPM 2 GPM 1 HEAD 2 HEAD 1 Affinity Laws 2 2 3 3 = = = = =

16. Hydronic System Basics NPSHA & NPSHR P NPSHA P B Foot Check - (FC) h L Strainer - (S) P P P NPSHA = (+P B ) + (-FC) + (-h L ) + (-P P ) + (-S) Pipe Pressure Drop

17. Hydronic System Basics P NPSHA P B Foot Check - (FC) 10’ Strainer - (S) 8’ P NPSHA = (+P B ) + (-FC) + (-h L ) + (-P P ) + (-S) Pipe Pressure Drop P B - 14.7 PSI (34’) P NPSHA = (+34) + (-4) + (-10) + (-8) + (-3) P NPSHA = 9’ NPSHA & NPSHR - Suction Lift

18. Hydronic System Basics NPSHA & NPSHR - Flooded Suction P NPSHA 8’ Pipe Pressure Drop P B - 14.7 PSI (34’) Strainer - (S) 10’ P B P NPSHA = (+P B ) + (-FC) + (-h L ) + (-P P ) + (-S) P NPSHA = (+34) + (-4) + (+10) + (-8) + (-3) P NPSHA = 29’

19. Total system HEAD & FLOW requirements through two parallel pumps Total System Head 1/2 Total Flow 1/2 Total Flow Hydronic System Basics Parallel Pumps

20. Two pumps in operation Each pump Head (ft) Flow (gpm) Hydronic System Basics Parallel Pumps

21. Total system HEAD & FLOW requirements through two series pumps Total System Flow 1/2 Total Head 1/2 Total Head Hydronic System Basics Series Pumps

22. Hydronic System Design Flow (gpm) Two pumps in operation Each pump Head (ft) Series Pumps

24. Hydronic System Types Closed Loop System

25. Hydronic System Types Direct Return System

26. Hydronic System Types Reverse Return System

29. Primary – Secondary Piping Basic Example

30. Primary – Secondary Piping Flow in the Common Pipe

31. Primary – Secondary Piping Finite Analysis of Common Piping Primary Return Secondary Return Secondary Supply Primary Supply

32. Primary – Secondary Piping Law of the Tees

34. Primary – Secondary Piping Cross-over Bridge Piping - Underslung

35. Primary – Secondary Piping Cross-over Bridge Piping - Overhead

36. Primary – Secondary Piping Correct Pump Location

37. Primary – Secondary Piping INCORRECT Pump Location

38. Primary – Secondary Piping What is the Flow Rate in the Common Pipe?

39. Primary – Secondary Piping What is the Flow Rate in the Common Pipe?

40. Primary – Secondary Piping Injection Pump Systems

41. Primary – Secondary Piping 3-Way Valve Systems

42. Primary – Secondary Piping 2-Way Valve Systems

43. Primary – Secondary Piping Fixed Temperature Control

44. Primary – Secondary Piping Modulating Temperature Control

45. Primary – Secondary Piping Modulating Temperature Control

46. Variable Flow / Variable Speed

48. Variable Flow Systems Constant Flow System

49. Variable Flow Systems Constant Speed - Variable Flow System

50. Variable Flow Systems Variable Volume System HP

52. Hydronic System Basics GPM 2 GPM 1 HEAD 2 RPM 2 RPM 1 HEAD 1 HP 2 HP 1 RPM 2 RPM 1 RPM 2 RPM 1 HP 2 HP 1 GPM 2 GPM 1 GPM 2 GPM 1 HEAD 2 HEAD 1 Affinity Laws 2 2 3 3 = = = = =

53. Variable Flow Systems 12.5HP 1800 RPM 1.6HP 950 RPM HP 2 12.5 = 900 1800 3 HP 1 = 1.6 HP

54. Variable Flow Systems

55. Variable Flow Systems

56. Variable Flow Systems SOURCE SOURCE System Criteria 2 - 100 Ton Chillers 2 - 300 GPM @ 100’ Pumps Pumps 2 - 20HP No Standby System Pressure Drop Total of 75’  P Chiller Pressure Drop Total of 25’  P TOTAL INSTALLED HP - 40 HP LIMITED VARIABLE VOLUME - 30% MAX HP REDUCTION

57. Variable Flow Systems SOURCE SOURCE System Criteria 2 - 100 Ton Chillers 2 - 300 GPM @ 25’ Pumps 2 - 300 GPM @ 80’ Pumps Primary Pumps 2 - 3HP Secondary Pressure Drop Total of 80’  P Primary Pressure Drop Total of 25’  P Secondary Pumps 2 - 10 HP Running Standby TOTAL INSTALLED HP - 26 HP 2 - 10 HP VFDs w/ STAGING REQ’D

58. Variable Flow Systems DP Sensor Location – Sensor Across Coil Typical Setting Equals Design Pressure Drop Across the Coil, Control Valve, and Circuit Setter. Coil 10 - 15’ P.D. Control Valve 10 - 15’ P.D. Typical Total P.D. 20 -30’

59. Variable Flow Systems DP Sensor Location – INCORRECT

60. Variable Flow Systems DP Sensor Location – INCORRECT

61. Variable Flow Systems DP Sensor Location – Correct

62. Variable Flow Systems DP Sensor Location – Correct

63. System Examples Chilled Water – Direct Return with Variable Speed

64. System Examples Chilled Water – Reverse Return with Variable Speed

65. System Examples Boiler Water – Direct Return with Variable Speed

66. System Examples Boiler Water – Reverse Return with Variable Speed

67. System Examples Primary – Secondary - Tertiary

68. System Examples Primary – Secondary Zone Pumping

69. System Examples Campus / District – Primary – Secondary - Tertiary

70. Special System Piping

71. Chilled Water Piping Examples

72. Tenant Use Pumps Tower Condenser Tenant Unit Tenant Unit Main Building Chiller

73. Tenant Use Pumps PDt Main Building Chiller Hst Ht PDrp PDsp PDs PDpt PDc PDt - Tower Pressure Drop PDsp - Suction Pipe Pressure Drop PDs - Strainer Pressure Drop PDpt - Pump Trim Pressure Drop PDc - Condenser Pressure Drop PDrp - Return Pipe Pressure Drop Ht - Tower Height - Static Lift Hst - Building Static Height Condenser

74. Tenant Use Pumps PDt - 15’ Main Building Chiller Hst - 100’ Ht - 10’ PDrp - 8’ PDsp - 8’ PDs - 3’ PDpt - 6’ PDc - 25’ ONLY STATIC PRESSURE SEEN AT PRESSURE GAUGE ON SUCTION OF PUMP P1 - 43 PSI Pump OFF Condenser P1 P2

75. Tenant Use Pumps PDt - 15’ Main Building Chiller Hst - 100’ Ht - 10’ PDrp - 8’ PDsp - 8’ PDs - 3’ PDpt - 6’ PDc - 25’ SUCTION SIDE OF PUMP - STATIC PRESSURE MINUS PDsp. AND MINUS PDs P1 >> 100’ - 8’ - 3’ = 38.5 PSI DISCHARGE SIDE OF PUMP - SUCTION PRESSURE PLUS PUMP HEAD (75’) P2 >> 38.5 PSI + 75’ = 71 PSI Pump On Pump Head = PDsp + PDs + PDpt + PDc + PDrp + Ht + PDt Condenser P1 P2

76. Tenant Use Pumps PDt Main Building Chiller Hst Ht PDrpa PDspa PDs PDpt PDc Ht - Tower Height - Static Lift Hst - Building Static Height PDspb PDrpb Hsta Hstb PDtenant PDt - Tower Pressure Drop PDspa - Suction Pipe Pressure Drop a Length PDspb - Suction Pipe Pressure Drop b Length PDs - Strainer Pressure Drop PDpt - Pump Trim Pressure Drop PDc - Condenser Pressure Drop PDrpa - Return Pipe Pressure Drop a Length PDrp b- Return Pipe Pressure Drop b Length Pdtenant - Tenant Loop Total Pressure Drop Condenser Tenant Unit

77. Tenant Use Pumps PDt - 15’ Main Building Chiller Hst - 100’ Ht - 10’ Pdrpa - 6’ Pdspa - 6’ PDs - 3’ PDpt - 6’ PDc - 25’ PDspb - 2’ PDrpb - 2’ Hsta - 80’ Hstb - 20’ Pdtenant - 25’ Tenant Pump Off - Main Pump On P3 - STATIC PRESSURE A MINUS PDspa. P3 >> 80’ - 6’ = 32 PSI P4 - DISCHARGE SIDE OF PUMP - SUCTION PRESSURE PLUS PUMP HEAD (75’) MINUS PRESSURE DROPS P4 >> 71PSI - 6’ - 25’ - 20’ - 2’ = 48PSI Difference P3 - P4 = 16 PSI (37’) Condenser Tenant Unit P3 P4

79. Tenant Use Pumps Tenant Use Pumps Must be with the rest of the condenser water pumping system in mind. Never size a tenant use system, for only the tenant loop pressure drop. Typical Pump Size 15 GPM @ 100’ TDH Tower Condenser Tenant Unit Tenant Unit Main Building Chiller

80. Chiller Water Piping Examples

81. Chiller Water Piping Examples

82. Chiller Water Piping Examples

83. Chiller Water Piping Examples

84. Chiller Water Piping Examples

85. Chiller Water Piping Examples

86. Chiller Water Piping Examples

87. Boiler Piping Examples

88. Boiler Piping Examples

89. Boiler Piping Examples

90. Boiler Piping Examples

91. Boiler Piping Examples

92. Boiler Piping Examples

93. Boiler Piping Examples

94. Boiler Piping Examples

95. Boiler Piping Examples

96. Boiler Piping Examples

97. Boiler Piping Examples

99. Hybrid Boiler System

100. Boiler Piping Examples

102. Questions???

103. Thanks!