Hydronic Basics / Primary-Secondary Pumping
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Transcript of Hydronic Basics / Primary-Secondary Pumping
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Hydronic System Piping Design
Presented by:
Dan Watkins, LEED AP
Bornquist, Inc.
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Topics to Cover
• Hydronic System Basics• Hydronic System Types• Primary – Secondary• Variable Flow / Variable Speed Systems• Piping Design Examples
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SOURCE LOAD
Hydronic System BasicsIn a Hydronic System
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SOURCE LOAD
Hydronic System BasicsSource & Load connected by piping
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SOURCE LOAD
Hydronic System BasicsFluid is circulated by a pump
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Hydronic System Basics
• Could it really be this simple?• What about different system types?• What about multiple zones?
• Let’s start with how to size a pump.
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Hydronic System Basics
• To size a pump you need to know required flow rate for the system and piping pressure drop.
• Flow rate is based on amount of heat to be transferred.• BTUh = 500 x ΔT x GPM• ΔT is the temperature drop desired in the system.• BTUh is the amount of heat to be transferred.
• Pressure drop is based on the flow rate through a given piping system.
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Hydronic System BasicsLet’s design a simple system together!
Boiler
200,000 BTUh
AHU Coil
20 GPM
Boiler = 5’ TDHAHU = 10’ TDHPiping = ???
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Hydronic System BasicsLet’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
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Hydronic System BasicsLet’s design a simple system together!
Boiler
200,000 BTUh
AHU Coil
20 GPM
Boiler = 5’ TDHAHU = 10’ TDHPiping = 4.41’ TDH
System Capacity:20 GPM @ 19.41’
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Hydronic System Basics
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GPM2 GPM1
HEAD2
RPM2
RPM1
HEAD1
HP2 HP1
=
= =
=
=
RPM2
RPM1
RPM2
RPM1
HP2 HP1
GPM2
GPM1
GPM2
GPM1
HEAD2 HEAD1
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Hydronic System Basics
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Hydronic System BasicsPoint of No Pressure Change – Expansion Tank Location
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Hydronic System BasicsExpansion Tank at Suction of Pump - Correct
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Hydronic System BasicsExpansion Tank at Discharge of Pump - INCORRECT
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NPSHA & NPSHR
PNPSHA
PB
Foot Check - (FC)
hL Strainer - (S)
PP
PNPSHA = (+PB) + (-FC) + (-hL) + (-PP) + (-S)
Pipe Pressure Drop
Hydronic System Basics
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PNPSHA
PB
Foot Check - (FC)
10’ Strainer - (S)
8’
PNPSHA = (+PB) + (-FC) + (-hL) + (-PP) + (-S)
Pipe Pressure Drop
PB- 14.7 PSI (34’)
PNPSHA = (+34) + (-4) + (-10) + (-8) + (-3)
PPNPSHANPSHA = 9’ = 9’
NPSHA & NPSHR - Suction Lift
Hydronic System Basics
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NPSHA & NPSHR - Flooded Suction
PNPSHA
8’ Pipe Pressure Drop
PB- 14.7 PSI (34’)
Strainer - (S)10’
PB
PNPSHA = (+PB) + (-FC) + (-hL) + (-PP) + (-S)
PNPSHA = (+34) + (-4) + (+10) + (-8) + (-3)
PPNPSHANPSHA = 29’ = 29’
Hydronic System Basics
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Total system HEAD & FLOW requirements through two parallel pumps
Total System Head
1/2 Total Flow1/2 Total Flow
1/2 Total Flow1/2 Total Flow
Hydronic System Basics
Parallel Pumps
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Two pumpsin operation
Each pump
Head(ft)
Flow(gpm)
Hydronic System Basics
Parallel Pumps
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Total system HEAD & FLOW requirements through two series pumps
Total System Flow
1/2 Total Head1/2 Total Head 1/2 Total Head1/2 Total Head
Hydronic System Basics
Series Pumps
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Flow(gpm)
Two pumpsin operation
Each pumpHead
(ft)
Hydronic System DesignSeries Pumps
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Hydronic System TypesOpen Loop System
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Hydronic System TypesClosed Loop System
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Hydronic System TypesDirect Return System
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Hydronic System TypesReverse Return System
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Primary – Secondary Piping
• Primary – Secondary Pumping: Was developed by Bell & Gossett in 1954 as a method to increase system temperature drops, decrease total pump Horse Power and increase system controllability. Systems utilizing low or medium temperatures were allowed due to Primary – Secondary pumping. Most modern systems utilize some variation of Primary – Secondary pumps.
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Primary – Secondary Piping
• “Common Piping” interconnects the Primary to the Secondary Circuit
• “Common Piping” should have minimal to no pressure drop to be designed correctly
• Hydraulically disconnects the two piping loops• Flow in one loop will not cause flow in the other loop
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Primary – Secondary PipingBasic Example
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Primary – Secondary PipingFlow in the Common Pipe
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Primary – Secondary PipingFinite Analysis of Common Piping
PrimaryReturn
SecondaryReturn
SecondarySupply
PrimarySupply
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Primary – Secondary PipingLaw of the Tees
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Primary – Secondary Piping
• Secondary pipe pump sized for pressure drops A-B, B-C, C-D, D-E, E-G, G-H, H-I
• I-A should have no pressure drop.
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Primary – Secondary PipingCross-over Bridge Piping - Underslung
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Primary – Secondary PipingCross-over Bridge Piping - Overhead
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Primary – Secondary PipingCorrect Pump Location
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Primary – Secondary PipingINCORRECT Pump Location
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Primary – Secondary PipingWhat is the Flow Rate in the Common Pipe?
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Primary – Secondary PipingWhat is the Flow Rate in the Common Pipe?
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Primary – Secondary PipingInjection Pump Systems
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Primary – Secondary Piping3-Way Valve Systems
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Primary – Secondary Piping2-Way Valve Systems
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Primary – Secondary PipingFixed Temperature Control
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Primary – Secondary PipingModulating Temperature Control
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Primary – Secondary PipingModulating Temperature Control
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Variable Flow / Variable Speed
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Variable Flow Systems• Constant Speed / Variable Volume
• Utilizes 2-way valves• Pump Energy is reduced
• Variable Speed / Variable Volume• Utilizes 2-way valves• Pump Energy is reduced• Uses VFDs to reduce pump speed
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Variable Flow SystemsConstant Flow System
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Variable Flow SystemsConstant Speed - Variable Flow System
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Variable Flow SystemsVariable Volume System HP
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Variable Flow Systems
• Variable Speed gives reduced HP• Variable Speed allows for easy pump balancing• Variable Speed also acts as a soft starter• Variable Speed drives are getting less costly• Variable Speed is not a mystery anymore
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GPM2 GPM1
HEAD2
RPM2
RPM1
HEAD1
HP2 HP1
=
= =
=
=
RPM2
RPM1
RPM2
RPM1
HP2 HP1
GPM2
GPM1
GPM2
GPM1
HEAD2 HEAD1
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Hydronic System Basics
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Variable Flow Systems
12.5HP
1800 1800 RPMRPM
1.6HP950 RPM950 RPM
HP2 12.5= 900
1800
3
HP1 = 1.6 HP
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Variable Flow Systems
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Variable Flow Systems
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SO
UR
CE
SO
UR
CE
System Criteria
2 - 100 Ton Chillers
2 - 300 GPM @ 100’ Pumps
Pumps
2 - 20HPNo Standby
System Pressure Drop
Total of 75’ P
Chiller Pressure Drop
Total of 25’ P
TOTAL INSTALLED HP - 40 HPLIMITED VARIABLE VOLUME - 30% MAX HP REDUCTION
Variable Flow Systems
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SO
UR
CE
SO
UR
CE
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 HPRunning Standby
TOTAL INSTALLED HP - 26 HP 2 - 10 HP VFDs w/ STAGING REQ’D
Variable Flow Systems
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Variable Flow SystemsDP Sensor Location – Sensor Across Coil
Coil
10 - 15’ P.D.
Control Valve
10 - 15’ P.D.
Typical Total P.D. 20 -30’
Typical Setting Equals
Design Pressure Drop
Across the Coil, Control Valve, and
Circuit Setter.
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Variable Flow SystemsDP Sensor Location – INCORRECT
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Variable Flow SystemsDP Sensor Location – INCORRECT
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Variable Flow SystemsDP Sensor Location – Correct
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Variable Flow SystemsDP Sensor Location – Correct
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System ExamplesChilled Water – Direct Return with Variable Speed
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System ExamplesChilled Water – Reverse Return with Variable Speed
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System ExamplesBoiler Water – Direct Return with Variable Speed
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System ExamplesBoiler Water – Reverse Return with Variable Speed
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System ExamplesPrimary – Secondary - Tertiary
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System ExamplesPrimary – Secondary Zone Pumping
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System ExamplesCampus / District – Primary – Secondary - Tertiary
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Special System Piping
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Chilled Water Piping Examples
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Tower
Condenser
Tenant Unit
Tenant Unit
Main Building Chiller
Tenant Use Pumps
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PDt
Condenser
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
Tenant Use Pumps
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PDt - 15’
Condenser
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
P1 P2
Tenant Use Pumps
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PDt - 15’
Condenser
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
P1 P2Pump Head = PDsp + PDs + PDpt + PDc + PDrp + Ht + PDt
Tenant Use Pumps
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PDt
Condenser
Tenant Unit
Main Building Chiller
Hst
Ht
PDrpa
PDspa
PDs PDpt
PDc
Ht - Tower Height - Static Lift
Hst - Building Static Height
PDspb PDrpb
Hsta
HstbPDtenant
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
Tenant Use Pumps
![Page 77: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/77.jpg)
PDt - 15’
Condenser
Tenant Unit
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’
P3
P4
Tenant Pump Off - Main Pump OnP3 - 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’)
Tenant Use Pumps
![Page 78: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/78.jpg)
PDt - 15’
Condenser
Tenant Unit
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’
P3
P4
Tenant Pump Sized for:
• Piping Pressure Drop
• Pump Trim Pressure Drop
• Tenant Unit Pressure Drop
• P4 - P3 Differential
Tennant Pump Head = Pdtenant + 37’ = 25’ + 37’
=62’
Tenant Use Pumps
![Page 79: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/79.jpg)
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
Tenant Use Pumps
![Page 80: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/80.jpg)
Chiller Water Piping Examples
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Chiller Water Piping Examples
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Chiller Water Piping Examples
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Chiller Water Piping Examples
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Chiller Water Piping Examples
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Chiller Water Piping Examples
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Chiller Water Piping Examples
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Boiler Piping Examples
![Page 88: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/88.jpg)
Boiler Piping Examples
![Page 89: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/89.jpg)
Boiler Piping Examples
![Page 90: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/90.jpg)
Boiler Piping Examples
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Boiler Piping Examples
![Page 92: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/92.jpg)
Boiler Piping Examples
![Page 93: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/93.jpg)
Boiler Piping Examples
![Page 94: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/94.jpg)
Boiler Piping Examples
![Page 95: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/95.jpg)
Boiler Piping Examples
![Page 96: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/96.jpg)
Boiler Piping Examples
![Page 97: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/97.jpg)
Boiler Piping Examples
![Page 98: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/98.jpg)
![Page 99: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/99.jpg)
Hybrid Boiler System
![Page 100: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/100.jpg)
Boiler Piping Examples
![Page 101: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/101.jpg)
Conclusions• Hydronic Systems require a lot of considerations.• Primary – Secondary is only one of many ways to
design, but is still a widely used design strategy.• Variable – Primary systems can work, but need
special considerations to prevent equipment problems.
• Variable Flow / Variable Speed systems have become the standard, but also require special considerations.
• System piping must be designed to satisfy the requirements of the building and installed equipment. No “One-Size-Fits-All” Solution.
![Page 102: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/102.jpg)
Questions???
![Page 103: Hydronic Basics / Primary-Secondary Pumping](https://reader036.fdocuments.net/reader036/viewer/2022062313/55783b11d8b42a1f5b8b4af8/html5/thumbnails/103.jpg)
Thanks!