Scribd
Upload
94 views74 pages

(O) B&G Training Manual Primary Secondary Pumping Application TEH-775

Bell & Gossett Training Manual volume

Uploaded by

snagglepuss.is.now
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
94 views74 pages

(O) B&G Training Manual Primary Secondary Pumping Application TEH-775

Bell & Gossett Training Manual volume

Uploaded by

snagglepuss.is.now
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
You are on page 1/ 74
BELL & GOSSETT BULLETIN NO. TEH-775 Primary Secondary Pumping Application Manual ’ Price $7.50 ( FLUID HANDLING I TT ‘© CoPvvGH 1868 rr CORPORATION TRAINING & EDUCATION DEPT. © O INTRODUCTION Primary-Secondary pumping has grown in stature since its concep- tfon by Bell and Gossett in 1954, The pumping arrangement was originally developed as a method of increasing allowable system temperature design drops, decreasing required pumping horsepower and increasing system control quality. The characteristics proposed as the reason for application have borne fruit; many low temperature and medium temperature systems have been designed using temperature drops that correspond closely to those normally associated with high temperature water systeus. Corresponding decrease in pumping horsepower as compared with conventional systems has also been proven. System control characteristics have been Leveled out and smoothed because the high pressure rise characteristic across control valves as caused by a single high head puup have been eliminated by primary- secondary breakdown of the system into a number of individually pumped low energy head circuits. In addition, however, many other applications have been developed; anti-freeze design, chiller and boiler pumping and control arrangements, newer terminal equipment control arrangements, zone switch- over methods, ete. Most modern larger systems use some variation of primary- secondary pumping technique. ‘This manual will review primary-secondary basics and introduce definitions and rules. Supplemental sections will cover control and equip- ment selection and specific design applications. PRIMARY~ SECONDARY BASTCS Primary-secondary pumping and control circuits are simple in theory and practice. Operation is based on this simple rule: WHEN TWO PIPING CIRCUITS ARE INTER-CONNECTED, FLOW IN ONE WILL CAUSE FLOW IN THE OTHER, TO A DEGRER DEPENDING UPON THE PRESSURE DROP IN THE PLPING COMMON TO ROTH. ‘The BSG Nono£lo circuit operates on this principle. The Mono- flo fitting provides a fixed orifice between the riser connections of the radiation circuit into the main and is installed in piping which ie common to both the radiation circuit and the main circuit, Flow in the radiation circuit occurs because of the orifice pressure drop. A typical Monoflo detafl is illustrated in Figure 1. youre circuit vowon sonor.o rene Zuonone — Zerewe common ro sory woyor.o waa EIENS. SeaMeNL See Mae Figure 1 - ZYPICAL MONOFLO CIRCUIT Were the Monoflo fitting renoved and the riser tees moved closer together, there would be practically no pressure drop between the points of riser connection. Due to the elimination of pressure drop in the piping common to both circuits, there would be practically no radiation ctreuit flow. ‘The previously outlined rule can, therefore, be restated: WHEN TWO CIRCUITS ARE INTER-CONNECTED, FLOW IN ONE WILL NOT CAUSE FLOW IN THE OTHER IF THE PRESSURE DROP IN THE PIPING COMMON TO BOTH IS ELIMINATED, —pomastic, cm RATER OUT Domestic WaTER STORAGE WILD FLOW. (Heer Source cour eet ee Bigcrion ERecieuating Pome CW.NLET 1 Figure 54 - CIRCULATED DOMESTIC WATER STORAGE TANK To BOILER THETANTANEGUS EXCHANGER ReciRCULATING Bowe. onrmvous i ‘SpeRATION=. Jew. ner ' Figure 55 - INSTANTANEOUS DOMESTIC WATER CONTROLLED FROM SHELL SEDE enum yous, Figure 56 - INDUSTRIAL FLUID TEMP, CONTROL (PUMP CAPACITIES EQUAL MAX, FLUID DRAW RATE) Sere owe aguas Figure 57 - SIMPLIFIED CHANGE-OVER PLUS HOT WATER RESET FOR HEAT-COOL SYSTEM A simplified change-over described in Figure 57 eliminates a great many operating change-over problems. The system pump operates continuously, and the change-over from heating to cooling, for vice versa, is effected by a simple two position switch which either energizes the boiler circuit or the chiller circuit. Boiler side activation starts the boiler and its injection pump. ‘he injection pump controls system water temperatures to reset requirements. Chiller side activation starts the chiller and its pump when the over-riding aquastat determines that system water temperature are low enough (85° neighborhood) to permit introduction into the chiller. ‘The change-over system described in Figure 57 has been applied with great success with cast iron boilers and with smaller steel boilers (less than 250 MBH gross). Application to large fire tube steel boilers should be referenced to the boiler manufacturer for his consideration taking into account the possibility of boiler "shock." Reference to non-shock application is made in Figure 69 , page 43 of this discussion. 5 18. Modulating Three Way Valve Control Application to Primary-Secondary; Preliminary Discussion Modulating three way valves are used in three different basic arrangements for Primary-Secondary application. een URED RISER suppty ‘COMMON Piping, Figure 58 - MIXING VALVE APPLICATION IN SECONDARY CIRCUIT Figure 59 - BYPASS OR DIVERTING 1 VALVE IN SECONDARY | 36 CONTINOUS COMMON PIPING RISER BLEED p cROSS-oveR Rives, UNDERSLUNG | FOOT Figure 60 - MIXING VALVE IN CROSS-OVER PIPING - UNDERSLUNG RISERS CONTINUOUS Figure 61 - MIXING VALVE IN CROSS-OVER PIPING - OVERHEAD For these application, the secondary zone pump is in continuous operation. Secondary water temperature is modulated up or down depending on the amount of primary water the three way valve admits into the secondary through the "bleed riser" and to the mix point. Control of the secondary cixcuit is thus vested in water tempera ture change--rather than the "flow change" control established by bypass control methods. The continuous flow established by P-S arrangements has important advantages where secondary zones are to be aeparately reset and is most a7 especially advantageous for freeze protection of air handling coils (see page 42) The application illustrated in Figure 58 has been in common usage for some time and despite some serious disadvantages has performed remarkably well. The disadvantages are: 1. The three way valve is interposed as a pressure drop @irectly at the secondary pump suction. Should valve pressure drop be high, the secondary pump can go into cavitation with resultant pump damage and reduced flow rate. 2, The Flo Control valve is intended to stop "one pipe" internal gravity flow from the primary to the secondary circuit when the three way is closed to the "bleed riser" (no load demand), While the valve will do this, it introduces other { problems: When the three way is closed to the bleed riser (primary) the Flo Control will act as @ check against entry of any water from the primary and into the secondary, A decrease contraction and a rapid reduction in secondary pressure. q H! in seondary circuit water temperature will then cause it it ‘he reduction in secondary pressure can again cause cavi- tation, 3. ‘The three way valve is generally "line sized" to the secondary flow rate. Should the full load flow requirement i from the primary be less than secondary flow, the valve is oversized. The valve will not be sized to the flow it is trying to control (cross-over or bleed riser flow). Under 38 these circumstances the three way valve is oversized and will have a limited control "stroke." ‘The bypass or diverting valve application, Figure 59, is preferred to the mixing application since it solves the secondary circuit pressure drop problem; the secondary pump does not have a restrictive suction pressure drop and the Flo Control Valve "swing" is such that secondary pressure can never be less than primary. Sizing of the three way valve to the "controlling flow" will still be a problem when required primary input flow rate is less than secondary. The arrangement shown in Figure 60 overcomes the problems noted above and is highly recormended. The arrangement has these advantages: 1, the control valve is sized to the cross-over bridge flow rate, which is always the controlling flow rate. 2, The particular location of the three way requires an “underslung" bleed riser if the operator is to be placed at the top of the valve. The underslung bleed riser provides a thermal anti-gravity flow leg which eliminates the need for the Flo Control Valve (an adap~ tation requiring the Flo Control is shown in Figure 61). 3. Pressure at the secondary circuit pump can never be less than primary circuit pressure as developed in the cross- over bridge. 4. Gross-over bridge can be balanced by proper selection (G, tating) of the three way valve. It will be noted that the conmon piping has been moved 39 from its conventional location in the cross-over bridge to a new location in the secondary circuit. 19. Pipe and Valve Sizing for Three Way Modulating Valve Application to The bleed risers are sized to the full load primary cross-over flow requirement and {s equal in size to the cross-over pipe size. The control valve is sized to the cross-over flow requirement and to some stated P.D, It would be usual to assign approximately 10° P.D, to this valve unless balance requirements dictate otherwise (see Hydronic System Flow Balance Manual). Sizing examples are illustrated for cross-over flow equal to secondary and for cross-over flow less than sccondary. SECONDARY CIRCUT 406.2" SECONDARY PUMP Seurnuouss 3 so sen arate TERRE. cross-over COMMON PIPING 2" cy 19 (ad cameo) Figure 62 - MODULATING THREE WAY PLPE SIZING: CROSSOVER FLOif= SECONDARY SECONDARY CIRCUIT 4066.62" SECONDARY PUMP SGNTINUOLS. PERATION. ACERS common piping 2° ty + BLEED Riser 1%4" —> Estee) cross-over i siasees ae leanne: Me Figure 63 - MODULATING THREE WAY; CROSS- OVER FLOW [ESS THAN SECONDARY 20. Modulating Three Way Control Application to Primary Secondary; Application Illustrations Pumps and valves together can perform control functions which valves alone or pumps alone cannot perform. In a closed loop hydronte circuit, mixing of two different temperature waters can only take place through action of a pump. The modulating control valve provides a "con- trolled modulation rate" of the mixed water which can be closely approached by the rapid "snap" on-off action of the injection pump. True mixed water temperature modulation can only be achieved by the modulating control valve pump combination, however. Some application examples follow: III CONTINUOUS ‘GPERATION (TEMP SENSOR peel SENSORY Figure 64 - INDOOR-OUTDOOR RESET OF SECONDARY a1 THERMOSTAT continuous GPERATION Oo Figure 65 - SPACE TEMPERATURE 7 CONTROL OF SECONDARY Flow, Switen To ALARM E TO cose AENAy' To Brags: Figure 66 ATR HANDLER-FREEZE PROTECTION PLUS AIR TEMP, CONTROL { eee j He { wo Flow set sot ; —] Figure 67 - CIRCULATED DOMESTIC WATER STORAGE TANK a FLUID ‘SUP | 2 }—— FLUID IN WILO FLOW. HEAT SOURCE L Figure 68 - INDUSTRIAL FLUID TEMP CONTROL. BOILER ‘80° Bypass OPE! 70° BYPASS CLOSED. ? S (PUMP STOP OC ee Rice) Figure 69 - SIMPLE CHANGE-OVER, RESET OF HOT WATER, BOILER SHOCK PROTECTION, CHILLER USED TO COOL DOWN "HOT" SYSTEM ON CHANCE-OVER CHILLER STEP CONTROL NOT EFFECTED BY CHANGES “IN SYSTEM FLOW RATE. In this {Llustration, the change-over is accomplished by a simple two position switch; activating either the chiller or boiler cireuite. For heating, the botler pump flovs the boiler continuously at an established flow rate. The three way valve resets system water as required--except when overridden by a high temperature difference signal between boiler supply and return as might occur after a shut down (cold a system) or on a change-over (cooling to heating) and with the botler up to temperature. ‘the arrangement shown will "bleed" systen water into the boiler circuit at a controlled rate until full reset temperature is reached. For cooling, the chiller flow rate is continuous, eliminating chiller load control problems as often caused by aystem flow variation, ‘The three way valve permits immediate use of the chiller to cool down residual hot system water during a change-over from heating to cooling The three way opens to bypass with entering chiller water over 80° and modulates to full open to the system when chiller entering water ts 70°, A chiller pump and chiller stop override aquastat with a manual re-start 4s set for approximately 90° as a secondary safety to prevent entry of hot water into the chiller. cuir, AIR Wate Pus culver, constant FLOW acu oyaon ) Subtract cross-over bridge retura temp. from primary supply. Step #2: Determine Cross-over bridge flow rate; this will be determined by secondary circuit load in MBH and cross over bridge AT. Example: A two pipe reverse return primary circuit is to serve four secondary circuits, Each secondary circuit is designed for 20° temperature drop. The following secondary circuit loads, flow rates, and supply-return temperatures will apply. Secondary Circuits; loads, flow rates and temp. Flow Mean Supply ‘Return Gixeuit Load Load Rate ‘Temp. ‘Temp. ‘Temp. # MBH Type @20° tT °F °F oi L 200 Baseboard 20 200 210 190 2 2000 Fan Coil —200 140 150 130 3 500 Panel 50 110 120 100 4 500 Air 50 180 190 170 Handler Secondary circuit return temperatures and loads will now be used for evaluation of cross-over bridge design temperature drops and required flow rates for a primary supply temp of 220°F. Gross-over Cross-Over Secondary Primary Return Temp. Cross-over Circuit — Load Supply = Secondary temperature Cross-over # oH ‘Temp. Return Drop Flow Rate 1 200 220 190 30 13.3 2 2000 220 130 90 45 3 500 220 100 120 8.5 4 500 220 170 50 20 The two pipe reversed return primary circuit would then be pipe sized to the flow rates shown in Figure 80. CROSS-OVER CROSS-OVER CROSS-OVER CROSS-OVER. BRIOGE Flow BRiD6e FLOW BRIDGE FLOW BRIDGE FLOW eiRcuiT®) circuit = ciacurr”s circuit 4 IBD GRM, 45GRM., | 86GRM, 20 ERM. ’ Figure 80 - REVERSE RETURN PRINARY CIRCUIT FLOW RATES - DESIGN EXAMPLE It will be noted that the overall load of 3,200 MBH will be carried by a primary flow rate of 86.8 GPM. The reswiting over-all temp- erature drop will then be approximately 75°AT. Primary flow rates could be further reduced by an increase in primary supply water temperature. The procedure outlined above differs from conventional practice where distribution flow rates are stated to a fixed overall design temp- erature drop; usually 20° AT. The difference in primary distribution flow rates is large; 320 GPM for the fixed 20° AT design as against 86.8 GPM for the primary-secondary "separate evaluation" design method. Tae 75° resultant temperature drop compares favorably with many WTW (400°) designs. The two pipe reversed return example design could be controlled as illustrated: 20 GPM, “WORCTION POM Zo oem £6.26 620 30.8 6PM, Figure 81 - POSSIBLE SECONDARY CIRCUIT CONTROL ‘ARRANGEMENTS - DESIGN EXAMPLE The primary circuit two pipe direct return design {s illustrated below for the cross-over bridge flow rates determined in the design example. CIRCUIT 4 ae 43 “4 cH GROSSOMER Linscem. aseAM © ocarn to aan, i 6.86PM. CAS GAM. Figure 82 - DIRECT RETURN PRIMARY CIRCUIT FLOW RATES - DESIGN EXAMPLE ‘The two pipe direct return circuit will often be in hydraulic unbalance because of differing circuit lengths. The balance problem is often solved by either/or: 1 Use of Elo indicators on cross-over bridge (see Pigure 83). Use of high pressure drop (15 to 25 ft.) three way valves in each cross-over bridge (see figure 84). VY FLO INDICATOR Figure 83 - FLO_INDICATOR IN CROSS-OVER BRIDGE; DIRECT RETURN DESIGN INA VALVE SELECTED FOR Wich PRESSURE OROE Ar'besign Flow RATE. Figure 84 - HIGH P.D, 3 WAY IN EACH CROSS- OVER BRIDGE; DIRECT RETURN DESIGN ‘The one pipe primary efreuit distribution main requires special design techniques. 25, One Pipe Primary Main Design The one pipe primary distribution main has unique advantages over the more conventional two pipe, because balance is automatidally estab- lished by the design procedure and because of cost saving possibilities. The 'bne pipe" design is predicated (for either heating or cooling) on each secondary circuit having primary circuit water temperatures available at the secondary circuit supply which will meet secondary circuit requirerents. Example: A one pipe primary main witl serve four secondary circuits. Each secondary is designed for 20° temperature drop. The following secondary cixeuit loads, flow rates and supply-return temperatures will appl: Flow Mean Supply Return Circuit Load Load Rate Temp ‘Temp ‘Temp MBH Type @20° T _ °F °r oF 1 200 Baseboard 20 200 210 190 2 2000 Fan Coil 200 140 150 130 3 500 Panel 50 110 120 100 4 500 Air 50 180 190 170 Handler Step #1: Determine one pipe main flow rate. ‘The last circuit (#4) requires 190° supply temperature for sec- ondary cireuit design conditions. Given a 240° primary supply temperature, the primary circuit can be designed to a 50° AT for the load represented by the first three circuits (HL, #2, and #3). ‘The load summation for the first three circuits will be 2,700 MBH os, (200 + 2,000 + 500), At 2 50°AT, this load represents 110 GPM flow rate. The 110 GPM flow rate will provide 190° supply water for circuit #4 and represents a total one pipe circuit temperature drop (including cir~ cuit #4) of approximately 60°. The one pipe circuit, as proposed, can then be laid out gigcurr gyncurre foomen. 000 Men, 210" SUPPLY 1S0°SUPPLY 190" TEMP, any) Vi T | circuits, cincurT#s o Boo mau, TaorsuPPLy Teor surece ( Figure 85 - ONE PIPE PRIMARY FLOW RATE DETERMENA- TLON FOR DESIGN EXAMPLE Step #2: Determine available one pipe primary main supply temp- erature at each secondary circuit. The available primary circuit temperature will be established by a sequenced determination of primary water temperature drop as effected by secondary load in MBH. As an example, circuit #1 has 2 200 MBH load. A primary flow rate at 110 GPM establishes a 3.6° (say 4°) primary temperature drop. Given a 240° entering primary temperature, the primary leaving temperature will be: 240 - 4 = 236°. As below: giRcur™ cigcortte Woo man. ovr 2000 wrest oT pire Balika Feow' tho sam 236%30"s200" rm ’ 2000.81. tle e.eM. Gar (use 4) 236AT Figure 86 - TEMPERATURE DROP SEQUENCE ONE PIPE PRINARY MAIN A complete temperature drop sequence is illustrated in Figure 87. gincurr circuit fog Man, dios suru B0* RETURN ‘por 10.2 PRiMaRy ARGU FLOW BATE, 190°. ‘200° | T | | circuit #4 cincurt 3, 500M. ‘309 Men [30s 'sueriy hot suppLy Vide ReroRN M8* RETURN Figure 87 - COMPLETE ONE PLPE TEMP DROP SEQUENCE ~ DESIGN EXAMPLE a7 i Step #3: Determine "injection" flow rate from primary to secondary. The "injection" or connecting riser flow rate from the primary and into the secondary will be established by available connecting tiser temp~ erature drop and secondary circuit load. Available connecting riser temperature drop will bez Available one pipe primary supply water temp minus secondary return temp. Using cireuit #1 as an example: Primary to secondary connecting injection riser temp drop = 240 - 190 = 50° AT 304T Pi Wechon RETURN INJECTION RIGER RISER @ 190° “5 @ rao", (EQUAL To sscom Y RETURN Tene eeatoRe) No een BYPASS aot “AVAILASLE ONE. (Bie aN reMber arene Figure 88 - CIRCUIT #1; INJECTION RISER TEMP DROP DETERMINATION Primary to secondary connecting injection riser flow rate is then determined on the basis of secondary load, For circuit #1, a secondary load of 200 MBH with 50° riser AT establishes a primary to secondary injection riser flow rate of 8 GPM, ‘The injection riser flow rates are illustrated in Figure 89 for the design example: OY eincuit™ cincut #2 eB GRM. 39.G.eM. 200 MB. 2000 MBH aT +50" ‘AT slog® jase asa WG.BM, 30 Gem. circuit #4 crecurr es Figure 89 - TOTAL CIRCUIT; INJECTION RISER FLOW RATES Step #4: Establish Secondary Control Methods. The secondary control methods used for one pipe primary main secondary control will depend on several factors: ’ a 1, Ratio of injection riser to secondary circuit flow ox to primary flow, 2, Location of common piping. 3. Location of pressure drop for inducing injection riser flow. Stop-Start Pump Control gigcort #1 foo'mBH LoD TOR -START BUMP CONTROL Figure 90 - STOP-START PUMP CONTROL FOR GIRGUIT #1; COMMON PIPING IN ONE PIPE MAIN When stop start operation of the secondary pump is used for control in one pipe application, the injection riser flow rate is induced by a restrictive pressure drop (order of 1" P.D.) placed in the secondary circuit. b. Injection control; circuit #1 Lone: 200 M.Bu. INJECTION PUMP CONTROL, seuss By 20amMn@ riot 20 GRM@190° er INJECTION PUMP To SPACE GR RESET CONTROL, BGRM.E 190° 236° 102 GAM. BY PAS IN common! PIPING: Figure 91 - INJECTION PUMP CONTROL The injection pump application is simple and does not require specific application rules. c. ‘lwo way Modulating Valve Control (NOTE: Flow rates same as Figure 91) e. TWO-WAY MODULATING. VaUve CONTROL. (ore: FLow RATES ‘SAME AS FIG. 91) 20.69m ResTRICTWe Jon 2 WAY MODULATING tae! Wo GAM COMMON PIPING(IN PRIMARY) Figure 92 - IWO WAY CONTROL; COMMON PIPING IN ONE PIPE MAIN “TWO-WAY MODULATING CONTROL. (wore: FLOW RATES ‘Same as Fra. 31) ‘Fitiné tin | secononay) 20 GRM.- z acam. 110 oRM. 2 Waist MODULAT wave ATING restrictive ro. Figure 93 - TWO WAY VALVE CONTROL; COMMON PIPING IN SECONDARY ‘Two way modulating valve control finds particular use in one pipe primary main application, ‘This is because the governing flow ratios (see Table II page 48) can almost always be set less than 30% by use of either Figure 92 or Figure 93. 1, In figure 92, the restrictive P,D. is placed in the secondary circuit. Flow ratio between the infection riser and secondary circuit will govern: Injection riser = 8 Secondary Circuit = 20 = 40% In this case flow ratios are over 30% and the control arrangement should not be used. 2. In Figure 93, the restrictive flow causing P.D. is placed in the one pipe main, Flow ratio between the injection riser and main will govern: Injection riser = 8 Main flow = 110 = 7.2% Flow ratios are less than 30% and application can be made with assurance of exceptional controllability. When two way valve control is applied to one pipe primary systems the restrictive pressure drop should be applied in a location that will yleld the lowest percentage flow ratio; below 30%, This is illustrated below for the design example: eRcuir circuit #2 RESTRICTION RESTRICTION | FLOW | NOCATION’ eH socaTion” | aatio Bor som} | w seconoany |7%,,1195%, INPRMARY. io 938% use restrictor — WOGRM TS PROMRRY reine ‘ae io 6m. caRcuiT 3) Restaiction Coearion. Fonco%] | m-stcononay | SHigr4B% — “IN PRIMARY. ONgT Use z-way valve WITH CIRCU (SEE Fe9E FOR CONTROL RFRLICATION) plow ware “hor ee “hor 10% Restaicrion teeatien 1W SECONDARY IN PRIMARY | Figure 94 - TWO WAY MODULATING CONTROL EXAMPLE VOR ONE PIPE PRIMARY The restrictive pressure drop for two way modulating valve i application would generally be set for approximately 3 PSI AP and the control valve signed accordingly; using circuit #1 as an illustration: circuit #4 RESTRICTIVE PO 8 GS... WITH auAY CONTROL VALVE WIDE OPEN. Figure 95 - TWO WAY MODULATING AND C | RESTRICTIVE P,D, RELATIONSHIP 62 4. Three way valve applicacion to one pipe primary main ‘The control valve application that should be made to circuit & in Figure 94 would be 3 way bypass or diverting--and in the secondary circuit as described in Figure 92: COMMON PIPING circurr #4 Figure 96 - THREE WAY BYPASS OR DIVERTING VALVE APPLICATION TO ONE PIPE PRIMARY MAIN Three way valves will not often need to be applied tp one pipe primary main secondary circuit control, because flow ratios will generally permit two way application. The bypass or diverting valve application is preferred over the mixing valve when applied in the secondary circuit because of sec- ondary circuit pressure problems (see item 18 page 36). 26. One Pipe Primary Main - Chilled Water Several large central station distribution systems have been installed using one pipe chilled water distribution mains. Complete design satisfaction has been obtained. Design is sophisticated; requiring integrated attention to temperature-rise dowa the main and diversity factors ‘The heat transfer area size in the secondary can also be affected by the main temperature rise. Gontrol of the secondary circuits would generally be established as two way valves in the "first secondaries" with 3 way application at the last secondary take-off. Considerable installation (buried conduit) savings can be obtained with highly predictable results, 27. Primary-Secondary application to "staged" construction. A large number of design plans prepared by Consultants are es- tablished for "staged" construction of schools, hospitals, factories, housing developments, ete. | When primary-secondary design procedure is applied, the primary | distribution system can be laid out full size; with cross over bridges installed for the future additions. Pumping and other equipment can be selected with complete predictability as to both initial and final results. Mere Pemeny stage”! fsecumer) | stace’ Cosa ie Cancers Cetasa's SEB Gee Ne ore Figure 97 STAGED P. DESIGN 28, New Heating addition to existing conventional two pipe distribution system. Many plants, schools, garages, etc. require heating off "add on! facilities to an existing hot water heating system. Primary-secondary application will usually make the addition possible - without changing the already installed distribution system. Example #1: ¢ i An industrial plant requires heating of @ new entry and watchnan's 64 structure (30 MBH). The new structure is located close to an existing re~ turn main for the present heating system. The return main is 2", flowing approximately 40 GPM at 180°. The installation is diagrammed below for atop-start pump control: COMMON PIPING 40-6.RM, RETURN Seem @ 160" ‘B GRM.@ 180° Fso mem. Figure 98 - EXAMPLE #1 PLOW DIAGRAM The new circuit is simply tapped into the existifg retura main; temperature control is achieved by thermostatic control of the secondary circuit pump. The following equipment selection criteria would apply: (D Pipe sizing to 3 GEM 3/4" (2) Pump selection to 3 GPM and circuit head; "75" booster. (3) Radiation selection to 30 MBH at 180° supply Example #2: A plant requires additional office space. The space is to be selectively cooled or heated using fan coil terminal units which require 140° mean water temperature for heating at 300 MBH load; a 15 ton cooling load is anticipated. An existing return main (180°) is located close to the proposed addition, The main is 3" size and flows 100 GPM. The basic "addition" flow diagram is shown in Figure 99. Lp Caren i Aguastar OveRiDE® Bs? wee = Figure 99 - EXAMPLE 2 FLOW DIAGRAM The new circuit is again tapped into the heating return main. The installation will not interfere with present distribution circulation and will selectively heat or cool by operation of a two position heat cool switch which activates either the heat injection pump or the chiller and its secondary pump. ‘The following equipment selection would apply: (1) Pipe size to 45 GPM (15 ton @ 3 GPH/ton) 2) Chiller at 15 ton. Co 3) Chiller pump at 45 GPH and chiller P.D. @) Secondary pump at 45 GPM and circuit P.D. (5) Injection pump at 300 MBH and 50° T= 12 GPM. (6) Injection flow rate not to exceed return main flow. In examples 1 and 2, the additional heating circuits have been tapped into existing return mains, using residual return heat, and in such a way that che original flow distribution has not changed. ‘The only effect is increased temperature drop applied to the existing pipe circuit, The same application procedures can be used for process loads, new air handlers, etc, The only application limits are return main £low rates and temperatures as applied to the "addition" heat transfer requirement s and, of course, existing boiler ability to handle the additional load. Should return main "tapping" not be feasible because of location C or new load requirements, the supply main can often be used. The common piping tap into the supply main will cause a temperature drop in supply water temperature which can often be overcome by simply raising the boiler supply water tenperature. Example #3: The previous design exauple (#2) is used as a base; the only difference being that a 3" supply main at 40 GPM and 200° temperature is to be used as the heat tap source. DESIGN Requines Sure @z00*To "COMMON PIPING Exigtine UNITS ‘surety MAIN 3" D ‘So gem oRisiNALLy 30 aP foo? ~wuection pume To" RESeT™ Figure 100- EXAMPLE 3 FLOW DIAGRAM; HEAT SOURCE TAP INTO SUPPLY MAIN ' The only difference between example 3 as compared with 2 will be a supply main temperature increase and a changed injection pump flow rate. A 300 MBH Load tap against a main flow rate of 40 GPM will es- tablish a.15° temperature drop in the main. The boiler aquastat would then have to be reset to 215° supply. The new conditions at the coumon piping tap into the supply main are as below: quency Teme To Busting Units GoRIGINAL 200 — COMMON FLPING sureyy main 3 SOGAM@ ZIB° Wn0 ais* Figure 101 - CHANGED CONDITIONS @ INJECTION PUMP ‘The new injection pump selection will be for 300 MBH at 85° temperature difference (215 - 130 = 85). The required injection flow rate will only be 7.2 GPU; a #100 booster pump could be used. a7 at New primary-secondary cross-over bridges can also be installed across existing supply and return mains. The additional cross-over flow requirement for the existing piping circuit can be held to a minimum by selection of the new terminal heat transfer equipment to a low mean water temperature requirement. Assuming the conditions established for exmple #2 are maintained except that a cross-over bridge is to be applied; the only change would be for an increased existing circuit flow of 12 GPM; as in figure 102. RETURN MAIN @ 180" SUPPLY MAIN @ 200" FLOW INCREASE OF 126.8, NEW CROSS OVER BRIDGE 12 G.AM.(300m8u.@70°8T) 200° sot IMJBETION PUMP —e teen. COMMON I ING Figure 102 » GROSS OVER BRIDGE APPLICATION TO EXAMPLE 2 Tt will usually be found that the minor existing circuit flow increase requirement established by new cross-over bridges for aystem addi- tion will not effect over: 11 system operation. Minimum flow increase is established by: 1, Selection of new secondary circuit heat transfer to low mean temperature requirements (140° forced convection). 2, Limitation of the new load. Many existing hot water circuits are designed to about 200° supply water temperature and 180° return. The existing network can be used for distribution of approximately three times its present heat conveyance ability by judicious application of 68 primary secondary principles. Example #4: ‘An industrial plant requires a major addition at a point remote from an existing boiler plant. Existing heat generating capacity is suffi- cient; the limitation being flow capacity of the existing distribution piping. RAGTION UNIT MATER AMR WNDLERE RADIATION cigcuit ‘ciRcuiT, ‘eancuit cigeuit 90" MtAN 140° MEAN WP MEAN 190" MEAN Figure 103 - EXISTING DISTRIBUTION PIPING CONVENTIONAL 20° A T DESIGN The existing distribution piping can be incréased to the order of three times its original heat conveyance ability by! au increase in design temperature drop. The increased design temperature drop can be attained by primary-secondary cross-over bridge control at each circuit distribution point, and by an increase in supply water temperature: TO RADIATION UNITHTR. NEW PLANT To AIR TO RADIATION EikcviT CiReuIT” ADDITION KANOLERS -ciReUIT pool seu | [RAR A ee fe} > Figure 104 - INCREASED TEMP DROP BY P-S_ APPLIC TION TO EXISTING DISTRIBUTION crRcUTT ‘PERNETS_ADOLTIONS WHILE USING EXISTING crrcurr, It will be noted that the original terminal unit heat transfer conditions remain the same; the only change is in greatly increased pipe heat conveyance ability. 29, Coil pump application of Primary-Secondary to Outside Air Handling Goil for freeze protection. Many outside air handling units are controlled by valves as illustrated below: RA yun, 2! waiter pee Z seins CER on ZB Lawmnw—| Z ssaarineo_.| Z cap are— Figure 105 - CONVENTIONAL 3 WAY CONTROL 10 ATR HANDLER QO Figure 106 ~ CONVENTTONAL 2 WAY CONTROL TO_ATR HANDLER Coil freeze-up can occur because of stratified cold air passage over bottom rows at a time that control valves have stopped coil flow due to load satisfaction. O Coil freeze, under these conditions, can be eliminated if con- tinuous coil flow is maintained at all times--and despite valve controlling position. Continuous coil pumping drives water through the stratified cold area fast cnough to prevent freeze, The water is then delivered to the i stratified warm return air area here {t {@ under continuova "reheat." The net result is additional coil freeze protection. Already installed, conventionally controlled, coils can be con- verted to the pumped coil installation by provision of a punp and a conmon piping bypass as below: Ra. yoga ) g Z i ong Aa i Z stkxtPieo 2g nee NEW CON tea BALANCE ‘ (continuous) -fo~over icine rrow ‘Switen Toren VAWES To cons. NEW COMMON PIPING ByPASS | CHECK vaWwe. cee Figure 107 - GOUL PUMP ADDITION FOR FREEZE PROTECTION 3 WAY VALVE (COMPARE WITH FIGURE 105) : EE Gj jo AEA! MU) Z one ena sees ue oa] NNN g Z Z = BALANCE ‘D=— OVER RISING FLOW ‘SWiten To OFEN Valves To cons NEW COMMON PIPING Gy- PAR acHecK VALVE Figure 108 - COLL PUMP ADDITION FOR FREEZE PROTECTION 2 WAY VALVE (COMPARE WITH FIGURE 106) n In this application, continuous coil flow will be provided so long as the coil pump is in operation. fo guard against inadvertent pump shut down, a flow switch is employed. This switch overrides normal con- trol and throws the control valve wide open to the coil. The check or Flo Control insures that coil flow will occur under these conditions. Overheating would soon bring corrective action. ‘The coil pump and conmon piping bypass are sized equal to or greater than flow rates correspon! ing to the initial full load coil and control valve flow selection points. The pump should be selected against the coil pressure drop and to a minimum head of 5' (booster pumps to 2") or to 10' (larger line mounted). In order to positively prevent any possibility of pump motor overload, as might be caused by "seriesed" operation of the coil pump with the main distribution pump, the operating pump differential head should be checked with the valve in a wide open position. Should th head be less than approximately 5' or 10' (see previous reference) the balance valve illustrated on figures 107 and 108 should be "cocked" back until the necessary differential head is obtained. n e FLUID HANDLING. TRAINING ir ecoio & EDUCATION DEPT. drs, «Monon rove eens TRANSPER DIVISION ITT

You might also like