1. Learning Outcomes Upon completion of this training one should be able to: Identify open loop and closed loop campus-type hydronic water system applications. Understand the variations of primary-secondary piped systems. Explain the importance of properly sized pump impellers. Explain the importance of sensors in hydronic systems. Communicate the importance of Life Cycle Costs for hydronic systems

2. 2 Hospital Building and Campus Piping

3. 3 Hospital Building Occupancy – office and patient areas Patient areas: 24 hours per day Office areas: 8 am – 5 pm, Monday - Friday Building Characteristics: Four story with basement 140,000 square feet per floor Standard construction

4. 4 Hospital – Stand alone operation Larger building Larger pumps Similar applications

5. 5 Medical Complex with Central Plant All buildings served from a single heating and cooling source located in a central plant Hot and chilled water are distributed to each building via piping loops

6. 6 Medical Complex with Central Plant Similarities All previous examples can exist in the same or larger scale Differences Pumps may be larger Distribution piping can be different Location of central plant is critical Multiple central plants may be tied together

7. 7 Campus Piping Systems

8. 8 Types of Piping Systems Closed Loop Systems Chilled Water Systems Hot Water Systems Open Loop System Condenser Water Systems Domestic Hot Water Recirculation Domestic Pressure Boosting (future session)

9. 9 Two Pipe Direct Return C H I L L E R C H I L L E R C H I L L E R Return Supply Pump Controller Secondary Pumps Primary Pumps Expansion Tank Air Separator Common Pipe

10. 10 Two Pipe Direct Return Common applications Basis of design for most CHW systems. Small, medium, or large size buildings Low or high rise Single or multiple buildings Single supply temperature

11. 11 Two Pipe Direct Return Piping Tips Common pipe design Tank Point of No Pressure Change (PNPC) Warmest water Air control and relief 2-way valves Size Location

12. 12 Two Pipe Direct Return Advantages Simplicity First Cost Efficient Disadvantages Over-pressurization Balancing Head requirement Thermally linked

13. 13 Primary-Secondary-Tertiary C H I L L E R C H I L L E R Zone A Zone B Zone C Optional Variable Speed Pump ∆P Sensor Modulating Control Valves Secondary Pump C H I L L E R Primary Pumps Tertiary Pumps Common Pipe Common Pipe

14. 14 Primary-Secondary-Tertiary Common applications Multi-building campuses Campuses with large diversity Campuses with buildings of varying heights Campuses with long piping runs Campuses with multiple production plants Campuses with elevation changes

15. 15 Tertiary Loop Piping T3 T1 Load MV Load MV Common Pipe T2 Tertiary Zone Pumps Tertiary Bridge Secondary Pump(s) Secondary Chilled Water Return Small Bypass Maintains Accurate Temperature Reading MV

16. 16 Primary-Secondary-Tertiary w/Plate HX Expansion Tank Air Separator C H I L L E R C H I L L E R Optional VS Pump ∆P Sensor Modulating Control Valves Secondary Pump C H I L L E R Primary Pumps Common Pipe Plate HX Tertiary Pumps Air Separator

17. Gasketed Plate Heat Exchanger

18. GP Heat Exchanger Flow From source Return to source To load From load

19. Gasketed Plate styles

20. 20 Tertiary Loop Piping w/ Plate HX Small Bypass Maintains Accurate Temperature Reading T3 T1 Load MV Load MV T2 Tertiary Zone Pumps Tertiary Bridge Secondary Pump(s) Secondary Chilled Water Return Small Bypass Maintains Accurate Temperature Reading T3 T1 Load MV Load MV Load MV T2 Tertiary Zone Pump Tertiary Bridge Secondary Pump(s) Secondary Chilled Water Return MV Plate HX Air Separator Expansion Tank Air Separator Expansion Tank

21. 21 Primary-Secondary-Tertiary Piping Tips When HX are used, additional tanks and air separator devices must be added to tertiary Controls for secondary and tertiary systems are independent

22. 22 Primary-Secondary-Tertiary Advantages Hydraulic isolation Thermal isolation Horsepower reduction Operational cost savings System performance optimization Disadvantages Additional piping Additional control valves First cost Over-pressurization of near zones unless plate hx is used More pumps

23. 23 Open Piped Systems Chiller Piping Condenser water piping Condenser water with economizer.

24. 24 Condenser Water Piping Return Supply Tower Evaporator Condenser Primary Pump(s) Secondary Pump(s) Condenser Pump(s) Chiller Sediment Separator Expansion Tank Air Separator

25. 25 Condenser Water w/ Economizer Return Supply Tower Evaporator Condenser Primary Pump(s) Secondary Pump(s) Condenser Pump(s) Head Pressure Control Valve Heat Exchanger Loads Sediment Separator Expansion Tank Air Separator

26. 26 Condenser Water Piping Condenser Water Tips Installation Keep pump suction flooded Watch NPSH Operation Air pockets End of curve Maintenance Strainers Air vents

27. 27 Best Practice Design

28. 28 Best Practice Design Why Constant speed pump Variable speed pump Optimize Pump Impeller

29. Best Practice Design Why ‒ Equipment over-sizing ‒ Cost penalty ‒ Mandate Optimize Pump Impeller 29

30. 30 Best Practice Design Constant speed pump Trim the impeller. Utilize the affinity laws. Follow the system curve. Save operating cost. First costs.

31. 31 Variable speed pump Impeller optimization Follows affinity laws Does not correct for poor engineering Over-sized pumps minimize turndown ratio Over-sized pumps and motors operate at lower efficiencies No added first costs Best Practice Design

32. 32 Primary Piping for Hot Water Systems Pump out of a boiler Keep the boiler at the lowest possible pressure Remember NPSH! Boiler 2 P1P2 Boiler 1 Best Practice Design

33. 33 Primary Piping for Chilled Water Systems Pump into a chiller Largest pressure drops after the pump Chiller Primary Pumps Chiller Best Practice Design

34. 34 System Bypass Options Best Practice Design Return Supply Pump Controller Secondary CS Pump(s) Common Pipe Chiller 2Chiller 1Chiller 3

35. 35 System Bypass Options Locate bypass near end of system Locate bypass near end of major loops Selectively leave 3-way valves Bypass with pressure activated control Variable speed considerations Best Practice Design

36. 36 Effect at minimum VFD speed Below 30% speed: CS, but still VV 120 110 100 90 80 50 40 30 20 10 70 60 0 1020304050 60708090100 0 % Flow Head 100 % Speed 30% Speed Best Practice Design

37. 37 1000 GPM Pump 1 Variable Speed: 500GPM @ 100 Ft Pump 2 Constant Speed: 500 GPM @ 100 Ft Wrong! Mixing CS and VS Pumps Best Practice Design

38. 38 Sensor Location Return Supply Pump Controller VFDs ∆P∆P Sensor Chiller 3 Chiller 2Chiller 1 Primary Pumps Secondary Pumps Best Practice Design

39. 39 Sensor Location The Traditional Way – Hydronically, the farthest load – Typically the largest, farthest load – Maximize the variable head loss – Multiple sensors are a benefit Best Practice Design

40. 40 Optimized solution not only for the pumps, but for the total system conditions Uncontrolled (constant volume) curve Constant pressure Proportional pressure (measured) Proportional pressure (calculated) Temperature control Best Practice Design

41. 41 Best Practice Design Q 100%25% H 1. Uncontrolled 2. Constant pressure 3. Proportional pressure (calculated) 4. Proportional pressure (measured) 5. Temperature control 0 20 40 60 80 100 100 80 60 40 20 0 Flow in % Effect in % 1. 2. 3. 4. 5. Get Additional Energy Savings

42. 42 Best Practice Design Total Efficiency vs. Control Modes

43. 43 Best Practice Design Comparison

44. 44 Best Practice Design Intelligent Control Integrating… Flow maximum, Flow minimum, Flow reset, Setpoint reset... into everyday operation

45. Intelligent Control Best Practice Design 45 Flow Limit 0255075100 Max Flow Potential saving compared to an unintelligent pump Potential saving compared with proportional pressure mode Duty point Additional saving with Flow Limiting Performance curve Min Flow

46. H(ft) P (W) Q (GPM) Intelligent Control – Constant Curve 46

47. Intelligent Control - Constant Curve (impeller trimming) H(ft) P (W) Q (GPM) 47

48. H(ft) P (W) Q (GPM) Intelligent Control - Constant Differential Pressure 48

49. H(ft) P (W) Q (GPM) Intelligent Control – Auto-reset 5 Feet 50 % H MaxH Max 49

50. H(ft) P (W) Q (GPM) Intelligent Control – Auto-reset 5 Feet Old Set Point New Set Point 50

51. Intelligent Control – Auto-reset Flow Limit 0255075100 Max flow Potential saving compared to an unintelligent pump Potential saving compared to proportional pressure mode Duty point Additional saving with Flow limiting Performance curve 51

52. 52