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Hydronic Systems

B-1

P-B-1

B-2

P-B-2

AS-1

ET-1

P-1

P-2

FCU FCU FCU FCU FCU FCU

BASIC HYDRONIC SYSTEM DESIGN

Generation EquipmentBoilers, Chillers, Cooling Towers, WWHPs, etc.

Terminal UnitsFan Coils, Chilled Beams, Finned Tube, Radiant, etc.

DecouplerClosely Spaced TeesPrimary Pumps

P-1 & P-2

DistributionPiping

Air / DirtSeparator

ExpansionTank

Secondary PumpsP-B-1 & P-B-2

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REFERRING TO PUMPS

HEATING

P-CH-1

P-CH-2

AS-2

ET-2

P-3

P-4

FCU FCU FCU FCU FCU FCU

CH-1

CH-2

B-1

P-B-1

B-2

P-B-2

AS-1

ET-1

P-1

P-2

FCU FCU FCU FCU FCU FCU

COOLING

PrimaryPumps

SecondaryPumps

SecondaryPumps

PrimaryPumps

AIR/DIRT SEPARATORSAir Vents at High PointsReduce Fluid VelocityChange Fluid DirectionReduce Pressure (Tangential)Coalescence (Microbubble)

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EXPANSION TANKS

Control pressure, control problemsExpansion tanks control thermal expansion and contraction of system fluid

Establish the point of “no pressure change”.

Full Acceptance Bladder type

Partial Acceptance Bladder type

Partial Acceptance Diaphragm type

Casing / Volute

CENTRIFUGAL PUMP COMPONENTS

Drain Pan

Suction

Discharge

Base

Motor

Bearing Frame Assembly

Coupler w/Guard

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CENTRIFUGAL PUMP COMPONENTS

Pump ShaftMechanical Seal

Bearing Frame Assembly

Impeller Woods Dura-Flex Coupler

Motor Shaft

Motor

COUPLER

Woods Dura-Flex Coupler

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BEARING ASSEMBLY

Bearing Frame Assembly

MECHANICAL SEAL

John Crane (Type 21) mechanical seal

Cover

Rotating Element

Pump Shaft

Slip-on Shaft Sleeve

Impeller

StationarySeat

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END SUCTION PUMPSEnd Suction Pumps

Most Popular StyleSuction / Discharge at 90ºSplit coupled allows servicing without disturbing pipe connections

Base Mounted, Split Coupled Foot Mounted, Close Coupled

IN-LINE PUMPSIn-Line Pumps

Suction / Discharge are In-LineDifferentiated by shaft orientationPipe supported, not fixed to structure

Horizontal In-Line Vertical In-Line

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SPLIT CASE PUMPSSplit Case

Two sets of bearings to support shaftAllows Access to both seals without moving motor or disturbing pipingUp to 1,500 HP

Horizontal Split Case Vertical Split Case

VERTICAL TURBINESVertical Lineshaft Turbine

Designed to Lift Liquid from Sump / TankMotor and Impeller are separatedImpellers “Push” better than “Pull”

Cooling Tower Sumps

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NEW “SMART” PUMPSSpeed varies without sensorsHigh Efficiency ECM

Electronically Commutated MotorA.k.a. DC Brushless Motor

Integral VFDSophisticated ElectronicsResidential to Light Commercial

TYPE GPM HD (FT.) HP RPM

HORIZ. IN-LINE 20 - 375 10 - 75 ¼ - 3 1760, 3500

END SUCTION 40 – 4,000 10 - 400 ⅓ - 200 1160, 1760, 3500

VERTICAL IN-LINE 40 – 12,000 10 - 400 ¼ - 600 1160, 1760, 3500

SPLIT CASE 100 – 18,000 20 - 500 3 – 1,500 1160, 1760, 3500

VERTICAL TURBINE 20 – 6,000 10 - 150 ½ - 150 1160, 1760

TYPICALCAPACITIES

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Pumps create Differential Pressure (ΔP)

Water Flows From Higher Pressure to Lower Pressure

The ΔP Induces Flow Against System Resistance

In an Open System the ΔP also Induces Lift Against Atmospheric Pressure and Gravity

CENTRIFUGAL PUMPFUNCTION

CENTRIFUGAL PUMP BASIC OPERATION

Impeller spin accelerates the liquid radiallyLiquid forced to the outside of the impellerCutwater diverts liquid out through the dischargeImpeller eye is point of lowest pressure

Impeller

Discharge

Suction

Cutwater

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The Pump Affinity Laws are a series of relationships relating:

Flow (GPM)Head (HEAD)

Horsepower (BHP)RPM Speed (RPM)Impeller Dia. (DIA)

Allow designers to estimate pump performance under different conditions

CENTRIFUGAL PUMPSAFFINITY LAWS

• GPM varies with RPM• Pump speeds up, flow increases• Pump slows down, flow decreases

• GPM varies with DIA• Large diameter impellers move more flow• Small diameter impellers move less flow

AFFINITY LAW #1

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AFFINITY LAW #1

1760 RPM60 Hz

1170 RPM40 Hz

580 RPM20 Hz

• HEAD varies as the square of the RPM• Pump speeds up, head increases exponentially• Pump slows down, head decreases exponentially

AFFINITY LAW #2

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AFFINITY LAW #2

• BHP* varies as a cube of RPM• Pump speeds up, BHP increases by cube• Pump slows down, BHP decreases by cube

AFFINITY LAW #3

BHP = Brake Horsepower is the actual power required to rotate the pump shaft. It is the portion of the motor HP that does the work.

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AFFINITY LAWS

Change in RPM (or DIA)

Change in GPM

Change in HEAD Change in BHP

x 1/2 x 1/2 x 1/4 x 1/8

Reducing Speed by Half:

Doubling Speed:

Change in RPM (or DIA)

Change in GPM

Change in HEAD Change in BHP

x 2 x 2 x 4 x 8

AFFINITY LAWSHow much HP is required to operate a 100 HP, 1760 RPM motor at half speed?

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AFFINITY LAWS

RPM GPM HEAD BHP

100% 100% 100% 100%

90% 90% 81% 72%

75% 75% 56% 42%

50% 50% 25% 12.5%

25% 25% 6% 1.2%

“Getting Into the Flow”

“the application of VFDs to constant speed pumps is now the fastest growing segment of the commercial pumping industry, a trend that improves (system) performance and efficiency…”

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• Soft Start• Same cost as a motor starter• Gentler on motors• Reduces inrush current

• Balancing without multi-purpose valve• Significant energy saving opportunity

• Variable Flow• Flow varies according to demand• Ultimate energy savings

WHY VFDs on PUMPS

Pump Curves

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200

100

10 0 20 0 30 0 40 0 50 0 60 0 70 0

PUMP CAN ONLY OPERATE ON ITS CURVE

IMPELLER CURVES

FLOW (GPM)

HEAD(FT)

Pump Curves

10”

13”

12”

11”

200

100

10 0 20 0 30 0 40 0 50 0 60 0 70 0

SYSTEM CURVE(PARABOLA)

FLOW (GPM)

HEAD(FT)

System Curve

FLOW = HEAD²( Y = X² )

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200

100

10 0 20 0 30 0 40 0 50 0 60 0 70 0

10 15 20

PUMP OPERATES WHERE SYSTEM AND IMPELLER CURVES INTERSECT

HP CURVES

IMPELLER CURVE

SYSTEM CURVE(PARABOLA)

FLOW (GPM)

HEAD(FT)

Horsepower Curves

OPERATING POINT

SYSTEM CURVE

200

2 PUMPS ON OPERATING POINT

100

IMPELLER CURVES

STATICHEAD

10 0 20 0 30 0 40 0 50 0 60 0

GPM IS ADDITIVE, HEAD REMAINS THE SAME

P1 or P2 P1 + P2

1 PUMP ON OPERATING POINT

Parallel PumpingCorrect Selection

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SYSTEM CURVE

200

2 PUMPS ON OPERATING POINT

100

IMPELLER CURVES

STATICHEAD

10 0 20 0 30 0 40 0 50 0 60 0

GPM IS ADDITIVE, HEAD REMAINS THE SAME

P1 or P2 P1 + P2

Parallel PumpingIncorrect Selection

One pump running does not intersect with system curve

Result = No Flow

Hydronic Piping Systems

Direct Return SystemReverse Return SystemPrimary-Secondary Pumping SystemInjection Pumping SystemSeries Pump SystemZone Pumping SystemSingle Pipe System

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Direct Return (First In/First Out)

AdvantagesShorter Pipe Runs

Lower first costLower pump head

DisadvantagesPoor Comfort

• Does not insure adequate flow to all terminal unitsNot Self Balancing

• Balance valves and balancing required

Reverse Return(First In/Last Out)

AdvantagesImproved Comfort

Greater assurance of adequate flow to all terminal units all times

Self BalancingDisadvantages

Longer Pipe RunsHigher first costHigher pump head

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Primary-SecondaryAdvantages

Improved Comfort Reduced complexity of balancing

Lower Operating Cost

Reduced pump horsepower by separating zones with different loads, operating temperatures, or pipe length

DisadvantagesIncreased Number of Pumps and First Cost

DECOUPLING

Distance Between Tees as Short as Possible (Tee to Tee).Pressure Drop Between Tees Will Determine Flow in Secondary Circuit when Secondary Pump is Off

WATER ALWAYS FOLLOWS PATH OF LEAST RESISTANCE

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Single Pipe

valves, balance valves, balancing, pipe and fittings

DisadvantagesRequires accounting for temperature cascade to provide adequate capacity of terminal units.

AdvantagesMaximum Comfort

• Insures adequate flow to all terminal units at all timesSelf balancing

Lower First Cost • Eliminate control

Injection PumpingAdvantages

Lower Operating Cost

• Operate secondary systems at optimum operating temperatures

Lower First Cost• Use one primary boiler system for multiple secondary

systems requiring different operating temperatures.

DisadvantagesIncreased Number of Pumps and First Cost

AdvantagesLower Operating Cost

Operate secondary systems at optimum operating temperatures

Lower First CostUse one primary boiler system for multiple secondary systems requiring different operating temperatures.

DisadvantagesIncreased Number of Pumps and First Cost

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Injection Pumping –Another Look!

Zone Loop

Building Loop

Injection

Series Pumping SystemAdvantages

Lower Operating Cost

• Reduced pump horsepower by separating zones with different loads

DisadvantagesIncreased Number of Pumps and First CostOperation of Pumps Affects Flow in Other Circuits

Pumps are not decoupledIncreased complexity of balancing

IHL-1

100°F

110°F

30000 BTU/H6.4 GPM

IHL-2

100°F

110°F

40000 BTU/H8.5 GPM

IHL-3

160°F

180°F

50000 BTU/H5.3 GPM

B-1

180°F

120000 BTU/H6.4 GPM

140°F

P-1

6.4 GPM12 FT

P-2

6.4 GPM7 FT

P-3

8.5 GPM7 FT

P-4

5.3 GPM7 FT

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Zone PumpingAdvantages

Lower Operating Cost

• Reduced pump horsepower by separating zones with different loads

DisadvantagesIncreased Number of Pumps and First CostOperation of Pumps Affects Flow in Other Circuits

Increased complexity of balancing

IHL-1

100°F

110°F

30000 BTU/H6.4 GPM

IHL-2

100°F

110°F

40000 BTU/H8.5 GPM

IHL-3

160°F

180°F

50000 BTU/H5.3 GPM

B-1

180°F

120000 BTU/H6.4 GPM

140°F

P-1

6.4 GPM12 FT

P-2

8.5 GPM12 FT

P-3

5.3 GPM12 FT

Single Pipe

Single Pipe SystemIndependent Decoupled Secondary Circuits for all Terminal UnitsUse Circulators Instead of Valves

No Control ValvesControl Zone Temperature with Circulators OnlyOn/Off or Variable Speed

No Balance ValvesSelf Balancing

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Next Generation Green Piping Systems

Integrated Piping SystemsHeating / Cooling / Fire Protection (Condenser Water)

• Trade Names – Tri Water

Cooling / Fire Protection (Chilled Water)• Trade Names – Total Comfort Solution, Ultimate Comfort Systems

Cooling / Domestic Cold Water (Chilled Water)• Trade Names – Total Comfort Solution

Heating / Domestic Hot Water (Hot Water)• Trade Names – Aqua Therm, Hydro Heat, Total Comfort Solution,

Ultimate Comfort Systems

Less Materials

Next Generation Green Piping Systems

Single Pipe LoadMatch® HVAC/Fire Protection Integrated Piping Main

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Thank You!