1. Upon completion of this training one should be able to: Identify different types of hydronic heating systems Identify key components in a simple hydronic heating system Understand the benefits of a variable speed/variable volume hydronic heating system Recognize the retrofit opportunities for converting cs/cv and cs/vv systems to vs/vs systems Learning Outcomes

2. 2 Multi-use Facility

3. 3 Occupancy – 140 persons Building Characteristics Single story 20,000 square feet (250’ x 80’) Standard construction

4. 4 What we will cover: Types of hydronic heating systems Closed loop perimeter heating Closed loop radiant systems Water source heat pumps Ground source heat pumps Piping methods Constant speed/constant volume Constant speed/variable volume Variable speed/variable volume Retrofit market Significant opportunities!

5. 5 HW Closed Loop Perimeter/ Fan Coil System

6. Manual balance valve 3-way control valve 2-way control valve Air separator System piping components

7. 7 Fan coil VAV box

8. 8 HW Closed Loop Radiant Floor/Snow Melt System Radiant Floor or Snow Melt Panels Boiler #2 Boiler #1 P1 P2 Secondary Pump Mixing Valve Primary Pumps P1 & P2* Redundant* Air Separator Common Pipe Expansion Tank

9. 9 HW Closed Loop Radiant Floor/Snow Melt System

10. 10 HW Closed Loop Radiant Floor/Snow Melt System

11. 11 Heat Pumps 60ºF HPWS 53ºF HPWR Heat Pump 160ºF HHWR 180ºF HHWS 53ºF CHWR Fan Coil Unit 45ºF CHWS Air 60ºF HPWS 67ºF HPWR 60ºF HPWR 60ºF HPWS Heat Pump Cooling Heating

12. Heat Pump Operation 12 53ºF HPWR Fan Air 60ºF HPWS Heating Water to Refrigerant Heat Exchanger Compressor Reversing Valve Refrigerant Coil Expansion Valve Refrigerant Piping

13. 13 Heat Pumps Types Water source Boiler and chiller Ground source Bore field / pond loop / well Hybrid A ground source plus supplemental heating or cooling

14. Closed Circuit Cooling Tower WSHP Buffer Tank ( Optional )) Compression Tank 14 Water Source Heat Pump (WSHP) Boiler WSHP Make-up Water Primary Pumps P1 & P2* Redundant* Expansion Tank Air Separator

15. 15 WSHP Components Cooling Towers Boilers

16. 16 Ground Source Heat Pump (GSHP) Bore Field GSHP Buffer Tank ( Optional ) Compression Tank GSHP Make-up Water HP Loop Pumps P1 & P2* Redundant* Expansion Tank Air Separator Bore Field Loop Pump

17. 17 GSHP

18. 18 Hybrid Ground Source Heat Pump Bore Field GSHP Buffer Tank ( Optional ) Compression Tank GSHP Make-up Water HP Loop Pumps P1 & P2* Redundant* Expansion Tank Air Separator Bore Field Loop Pump

19. 19 Hydronic Piping Systems Types: Constant Speed/Constant Volume (CS/CV) Piping & equipment requirements Deficiencies Energy usage Constant Speed/Variable Volume (CS/VV) Piping & equipment requirements Advantages Energy usage Variable Speed/Variable Volume (VS/VV) Piping & equipment requirements Advantages Energy usage

20. 20 CS/CV Piping System

21. 21 CS/CV System Deficiencies High return water temperatures Robs hot water from other coils at part loaded conditions Increases flow Adds additional boilers on line Boiler performance is reduced

22. 22 CS/CV System Load for Multi-use Facility: Chicago, IL Plot load profile Select pump for 108 gpm @ 36 ft

23. 40 35 30 25 20 15 10 5 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 Flow (gpm) Head (ft) 23 108 gpm @ 36 ft CS/CV Pump 97%

24. 24 Pump Energy Consumption - CS/CV CS/CV

25. 25 CS/VV HW Piping Systems Primary Pumps P1 & P2* *Redundant Return Supply Secondary Pumps P1 & P2* Boiler 1 Boiler 2* Air Separator Expansion Tank Air Separator Expansion Tank

26. 26 CS/VV Pumping Systems Add secondary pumps Add common pipe Add system bypass Add 2-way valves Eliminate 3-way valves…or

27. 27 CS/VV Pumping Systems Eliminate 3-way valves Disable 3-way valves Shut bypass valve Disconnect bypass pipe Actuator may be undersized for 2-way operation Does this make $ense?

28. 40 35 30 25 20 15 10 5 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 Flow (gpm) Head (ft) 28 108 gpm @ 36 ft CS/VV Pump Curve 97%

29. 29 CS/VV Advantages Lower return water temperatures Minimizes flow to coils Decreases secondary flow Reduces boilers on line Boiler performance is increased Ease of system operation Energy savings Preferred piping method

30. 30 Pump Energy Consumption - CS/VV CS/CV CS/VV

31. 31 VS/VV Pumping Add: Variable frequency drive (VFD) Programmable logic controller (PLC) Differential pressure sensors (∆P) Direct digital controls (DDC) Save 75% AOC versus CS/CV!

32. 32 VS/VV Hot Water Systems Secondary Pumps VSP1 & VSP2* ΔP Sensor Air Separator *Redundant Return Supply Boiler 1 Boiler 2* VS Pumps And Controls Expansion Tank

33. 33 Pump Curve Summary CS/CV 108 gpm @ 36 ft CS/VV VS/VV 108 gpm @ 36 ft 54 gpm @ 37 ft 54 gpm @ 9 ft

34. 34 108 gpm @ 36 ft Flow (gpm) Head (ft) 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 40 35 30 25 20 15 10 5 0 VS/VV Pump Curve

35. 35 VS/VV Advantages Optimizes return water temperatures Optimizes flow to coils Decreases secondary flow Reduces boilers on line Boiler performance is increased Ease of system operation Optimum energy savings

36. 36 Pump Energy Consumption - VS/VV CS/CV CS/VV VS/VV

37. 37 VS/VV Advantages Cost effective design Primary-secondary pumping Common pipe design 2-way valve operation Save 75% of pumping energy over CS/CV systems Save 50% of pumping energy over CS/VV systems

38. 38 Additional System Savings Additional sources of energy savings Boiler operation ΔT optimization Sources of first cost savings Pump sizing Boiler sizing Valve sizing Pipe sizing

39. 39 VS/VV Pumping Add: Variable frequency drive (VFD) Programmable logic controller (PLC) Differential pressure sensors (∆P) Direct digital controls (DDC)

40. 40 Demand More Magna3!

41. 41 HW Systems with VS Pumps Secondary Pumps VSP1 & VSP2* ΔP Sensor Air Separator *Redundant Return Supply Boiler 1 Boiler 2* VS Pumps And Controls Expansion Tank

42. 42 VS/VV Retrofit Opportunities Converting CS/CV to VS/VV Steam systems 3 pipe hot/chilled water systems One pipe hot water systems 3-way valve hot water systems Uncontrolled radiant systems Over-sized boiler pumps

43. 43 VS/VV Retrofit Opportunities Converting CS/VV to VS/VV CS 2-way valve HW systems CS three pipe systems Systems with poor ΔT control Systems with over-sized pumps Systems with local ΔP sensors Systems with single VS pumps

44. 44