BELL & GOSSETT BULLETIN NO. TEH-1275 Equipment Room Piping Practice Price $7.50 FLUID HANDLING I TT TRAINING & EDUCATION DEPT.EQUIPMENT (BOTLER) ROOM PIPING PRACTT 1. GENERAL DESIGN AND APPLICATION RULES ‘The following design and application rules apply to all equipment rooms whether intended for heating only, dual chilled and hot water, instantaneous chilled and hot (3 or 4 pipe) or zoned chilled and hot. 1, Distribution pumps must discharge into the piping systen with the com- pression tank connection located at the pump suction. J+ COMPRESSION TANKS#( AIR SEPARATORS ——|— ' RIGHT WRONG ‘TANK AT PUMP SUCTION ‘TANK AT POMP DISCHARGE Figure 1 - RIGHT AND WRONG PUMP LOCATION The wrong pump location will decrease system static pressure by an amount equal to the operating pump head. System circulation and mechan- ical pump troubles will occur. The properly Located pump increases system static pressure during operation and eliminates trouble potential. 2. PUMP SELECTION Distribution pumps should be selected to approximate curve mid- point, using flat curved pumps.No"oRIET™ Gro oF URVE ‘SLELCTION Rigut! wrone / wrone! muat CURVED WITH steep curveo— unt cORVEO— ORIFT ABILITY (MO DRIFT ABILITY NO ORT ABILITY Figure 2 - RIGHT AND WRONG PUMP SELECTIONS System distribution pumps should be selected for systen needs. ‘The Large multi-circufted hydronic system needs a pump selection that will help overcone circuit distribution problens. 3. PIPING SIZB AT PUMP SUCTION AND DISCHARGE Pipe size at the pump suction and discharge should conform to distribution main size; not to suction and discharge pump opening size. BI DISTRIBUTION MAIN BITE. 5’ DISCH-R.VALVES. PIPING VALVES SIZED ey Sects S"sucrioua mares WRONG /ronr pene eves “I PUMP PIPING E VALVES: IWSTALLED TO PUMP OPEMING SIZE Hip waorermeumon RicuTé waive DUTY WSTALED — WeOKe/TaIPLe-DUTY mstALED ‘To busrmeuTioN ibe ste. To rome oreame te FIGURE 3 - RIGHT AND WRONG PUMP PIPE AND VALVE SIZING Suction and discharge piping (and valves) sized to the pump opening works against system flow distribution needs because of unwarranted increases in equipment room pressure drop.4, PUMP SUCTION PIPE Lenora oO ‘The pump suction "straight" run pipe length should be at least 5 DIA. of suction pipe size to insure good pump entry conditions. ! aun WRONG: RIGHT: BAD PUMP ENTRY & GogD, PUMP ENTRY “NO” PIPING SUPPORT. FIGURE 4 - RIGHT AND WRONG PUNP ENTRY CONDITIO) 5. PUMP PIPING SUPPORT. Pump piping support should be provided as shown in Figure 4. The pump should not serve as a piping anchor. 6. MULTIPLE PUMP CHECK VALVES ' ) Check valves (conventional, Triple Duty or Flo Control) should be installed at each pump discharge when more than one pump is used in the equipment room. This applies whether the additional pumps are for standby, parallel operation or zone pumping. pons Rignr/ wrone/ INSTALL CHECKS FoR = CHECKS LEFT OUT. MULTIPLE Pumes. THIS MEANS. TROUBLE FIGURE 5 - MULTIPLE PUMP CHECK VALVES Trouble will develop when check valves are not installed because of reversed flow through non-operating pumps. When these pumps are started, they must overcome a heavy flow inertia load and will over~ load.7. ZONE PUMP STRAINERS Zone pumps should not use a single fine mesh strainer in the header piping. Clogging of this single strainer can lead to non-operation and freeze up in low pump head zones. ance 4 Seite ME Mes eae — Rieu! WRONG! FING MESH STRAINERS AT FINE Mesh STEAINER {ONE PuwP DISCHARGE; nce in Common HEADER. MESH STRAINER IN HERDRR. FIGURE 6 ~ STRAINER APPLICATION Fine mesh strainers are often used to protect control valves, etc. They are not needed for pump protection. When fine mesh steam type strainers are used, their best application point is either at the pump discharge or out in the systen. It is considered good practice to remove strainers from the water system after 2 to 3 months operation. While in use, the strainers should be watched continually for clogging. 8. AIR SEPARATOR LOCATION ‘The air separator should be located so that full system flow passes through it. RisuT) WRONG / Fou. system PLOW THRU PARTIAL SYSTEM FLOW ROLAWTTROL AIR SEPARATOR THROUGH AIR SEPARATOR. PIGURE 7 ~ FULL SYSTEM FLOW THROUGH SEPARATORoO IT. EQUIPMENT OR BOTLER ROOM PIPING PRACTICE; HEATING AND/OR COOLING AIR SEPARATION The following illustrates a series of specific application solutions for various Equipment Room problems: 1. FLOOR MOUNTED COMPRESSION TANK Floor mounted compression tanks are used because of Limited ceiling height above boilers or air separators and to eliminate special ceiling structure design necessary for large ceiling hung tanks. The basic problem concerning the floor mounted tank is intro- duction of separated air from an overhead point into the tank. ‘this problem is solved by the arrangement shown in Figure Ii-1. SMALL Ye" TAR SECONDARY. AIR SeeRRaToR: FIGURE II-1 - FLOOR MOUNTED COMPRESSION TANK In Figure II-1, main system air is liberated in the overhead main air separating Rolairtrol. This air is then pumped down into the small IAF type separator from which it is delivered into the bottom of the floor mounted tank. The small booster pump provides the driving energy head for delivery of overhead air to the tank. ‘This pump must be selected so that dts shut-off (no delivery) head is on the order of 2 to 3 £t. greater than the statfe height "H" shown in Figure II-L. ‘The connecting line from the small IAF to the tank must be large enough (at least 1") 80 that similtaneous counter passage of air into the tank and water from the tank back to the IAF will be assured.2. MULTIPLE BOILERS CONNECTED 10 A SINGLE COMPRESSION TANK A single tank is generally not recommended for interconnection with multiple air separators. This is because a pressure difference between the boiler will cause a flow in the header connection. This flow prevents delivery of separated air to the coapression tank. AIR BYPASSES TANK ‘AND RE-ENTERS svsTeM THROUGH BOILER #2. aor * ey jeoner” LER? t per WRONG! FIGURE IL-2 - SINGLE TANK CONNECTION TO MULTIPLE BOLLERS ‘The problem can be solved by a pumped header connection as schematically illustrated in Figure II-3. Swan iar VALVE PRESSURE DROP SEN ERS Aue Faccitene ation Taek, So TANK HEADER LING Fo SMALL LAF Aare = t 7 RIGHT! FIGURE IL-3 - PUMPED COMPRESSION TANK HEADER CONTAINS SMALL LAF ‘The single tank can also be floor mounted as in Figure II-4.SMALL BOOSTER Noresre re e-| Porpine, sal ECrion. FIGURE II-4 - MULTIPLE BOILERS WITH SINGLE FLOOR MOUNTED TANK; PUMPED COMPRESSION TANK HEADER 3. MULTIPLE ZONE _ATR SEPARATION Many larger systems are installed using multiple "reset" zones. Flow distribution problems have occurred because use of a single Rolairtrol or ABF does not comply with its full system flow objective through the air separator. FIGURE II-5 - MULITPLE ZONE RESET; FULL. FLOW DOKS NOT OCCUR THROUGH AIR SEPARATION A separate Rolairtrol can be placed on each zone and inter- connected with a single tank to meet the full flow objective.IIL Iv. SMALL IAF Fu FLOW ae Srarator. f |<} FIGURE 11-6 - MULTIPLE ZONE RESET; FULL, FLOW THROUGH EACH ZONE AIR SEPARATOR The small Booster pump must have a shut-off head greater than height "H". Its head must also be greater than the three-way valve pressure drop. See note on page 23 ZONE PIPING APPLICATIONS 1. MULTIPLE ZONE HEATING APPLICATION ‘The multiple zone heating application has led to many operating problems because of improper application. ‘One of the common problems is illustrated by an attempt to reduce cost by using a single return main for a nunber of zones; each zone having several circuits and several returns for each zone. UNWANTEO. FLOW in TONE, —} WRONG / @ PIGURE IV-1 ~ MULTIPLE ZONES, VALVE CONTROLLED, EACH ZONE WITH MORE THAN ONE ‘RETURN,ty ® UNWANTEO. Flow im ZONE WRONG / FIGURE IV-2 - MULTIPLE ZONES, PUMP CONTROLLED, EACH ZONE WITH NORE THAN ONE _RETURN @ In both Figures IV-1 and IV-2, the operating zone causes flow rate in the return main. Pressure drop in the return (as at A and B) in turn causes unwanted flow in the non-operating cone with an associated lack of control. On already installed systems, the only solution ib to install check valve in the zone circuit returns as required. The uncontrolled flow problems can be overcome during design by combining all zone circuit returns into a common zone return before entry into the main return. TONE CIRCUIT RETURN One ren TONE RIGHT / FIGURE IV-3 - MULTIPLE ZONE, ONLY ONE RETURN PER ZONEV. EQUIPMENT OR BOELER ROOM PIPING PRACTICE; HEATING 1. BOILER SHOCK PROTECTION “Boiler Shock" is a term that has been very loosely defined. In general, it refers to sudden thermal changes inside the boiler causing vapid and uneven contractions; in turn, tending to loosen boiler tubes with a final necessity for boiler retubing. Water tube and cast iron type boilers have, in general, a high resistance to boiler"shock". Larger fire tube type are generally more susceptible. Boiler shock frequently occurs in large systems waere week-end or might shut-down takes place. The sudden introduction of massive amounts of cold water into the hot boiler during start-up often causes trouble. Boiler shock can also occur in the conbination heating and cooling system when switching from chilled to hot operation. Reduced to fundamentals, control against "boiler shock" involves control of incoming "cold" water flow rate so that boiler temperatures are changed slowly. ‘SWAY TIMED To OPEN SLOWLY SWAY VeLVE CONTROLS ONLY ayaa nin never on START UR WRONG! 3 WAY OPENS IMMEDIATELY ON START UR Rieu FIGURE V-1 - 3-WAY OPENS FIGURE V-2 - 3-WAY OPENING 10 INMEDIATELY ON START-UP RESET REQUIREMENTS OVER-RIDDEN BY "TDM" OPENING CYCLE 10One of the methods used for "shock" protection employs a timed 3eway valve so that the boiler circuit is opened slowly to incoming cold system water. The timed cycle is generally on the order of 20 to 30 minutes from closed to fully open. A more sophisticated arrangement provides for continuous automatic protection against boiler "shock" by separate circulation of the boiler. sont FIGURE V-3 - SEPARATELY PUMPED BOILER; 3-WAY OPENING TO RESET OVER-RIDDEN ‘BY TEMPERATURE DIFFERENTIAL CONTROL ACROSS BOILER In Figure V-3, the boiler is continuously circulated at a constant flow rate. The flow rate corresponding to 20° to 40°AT at the maximum load draw condition. On a cold start, the boiler temperature differential controls 3-way valve opening; admitting controlled amounts of "cold" system water into the boiler circuit. As the system heats up, the 3-way opens more to the system until final controlling reset is obtained. 2, RESET METHODS Reset control can be obtained by valves alone, pumps alone or ‘by use of valves and pumps in combination. ntRIGHT / PICURE V-4 - CONVENTIONAL 3-WAY VALVE RESE! APPLIED 10 HEATING ONLY SYSTEM Conventional 3-way valve reset is best used for the heating only system where, under full load, the entire system flow passes through the boiler. Under these conditions, the valve is sized to the flow it is controlling; 1.e, flow from the boiler into the distribution main. The conventional 3-vay reset control is often mis-applied to combination heating and cooling systems. The mis-application concerns a fundamental proposition; that the control valve be sized to the flow it is controlling. WRONG! FIGURE V-5 - CONVENTIONAL 3-WAY RESET APPLIED T0 HEAT/COOL CHANGE -OVER; VALVE SIZED 10 DISTRIBUTION MAIN PIPE SIZE In Figure V-5, the 3-vay is sized to the main distribution pipe size, but is controlling the side branch boiler cireuit flow. Since the boiler ctreuit flow requirement at full load reset is only 18% (Nain AT or Boller AT Jijg=134 ) of the main flow rate. ‘the valve is obviously over-sized; it is sized to control, as an exanple, 300 GPM main flow, 2) but is used to control approximately 60 GPM boiler input flow. The situation can be corrected with a resultant saving in valve and boiler pipe sizing as in Figure V-6. USED To FORCE FLOW THROUGH tom sean nares ye Sehncane Ricut! Figure V-6 - THREE WAY RESET APPLIED TO HEAT/COOL CHANGE-OVER; VALVE SIZED TO FULL LOAD BOILER CIRCUIT FLOW RATE. Injection pumps are often used in a Primary-Secondayy Boiler con- nection for reset. Figure V-7 - INJECTION PUMP "RESET" The injection pump can be used for either heating only or for hheat/cool application. Injection pumps are sometimes used in multiples for boiler shock protection, When used in multiples, one pump is used for light load, and other pumpa are sequenced in as load increases. This particular arrangement is applied by Homer Bird, Consultant in Minneapolis, Minnesota. 13Reser MULTIPLE INUBCTION PUMP RESET. Figure V-8 - MULTIPLE INJECTION PUMP RESET On cold start up, the pumps are gradually sequenced in until reset conditions are reached, Multiple sual boilers are also used for reset control. This partic- ular method has the advantage of reducing boiler standby loss during light loads. Figure V-9 - MULTIPLE BOILER RESET In multiple boiler reset, only the operating boilers are at temperature, Standby loss is eliminated for the non-operating boilers resulting in lower operating cost. During light Load, only one boiler is “on as load or reset temperature requirements increase additional boilers axe sequenced “on. Boiler circuit pumps are often used to provide constant boiler flow, reduce control valve size and provide against boiler "shock." “reser Figure V-10 - SEPARATELY CIRCULATED BOLLER WITH "RESEI"; BOILER SHOCK OVERRIDE NOT SHOWN (see Fig. V-3) 3. MEDIUM TEMPERATURE (250° to 300°) BOLLER ROOM APPLICATION ‘The medium temperature system requires special consideration for its boiler room application; standard low temperature (less than 250°) piping ‘) configurations should not be used. 250 To 300" sone TaneeraTone, WRone! Figure V-11 - STD, L1W ARRANGEMENT SHOULD NOT BE _USED FOR MIW APPLICATION In MEW application, the main distribution pump is placed on the system return in order to reduce temperatures entering the pump.SYSTEM PRESSURIZATION UMAIN DISTRIBUTION PUMP g—_peot To 300° iin seraranon RiguT. Figure V-12 - MIW BOTLER ROOM ARRANGEMENT; WATER TUBE TYPE BOILER SEPARATELY CIRCULATED In this arrangenent, the main distribution pump is placed at the system return discharging into the water tube boiler. Constant flow is maintained in the boiler to help prevent tube burn-out. System pressurization is set to a minimum "fill" pressure equal to a saturation pressure corresponding to 25° above maximum leaving supply temperature; 300° supply establishes 325° saturation or about 85 psig min- imum £111 pressure. The boiler maximum operating pressure will be: Minimum Fill plus system pressure rise plus pump head. Location of the pump; discharging into boiler helps prevent boiler tube burnout. Steam to water exchangers are often used as a heat source for MIW application. Bish, Figure V-13 - MIW BOILER ROOM ARRANGEMENT STEAM TO WATER EXCHANGER 16VI. EQUIPMENT OR BOILER ROOM PIPING PRACTICE - CHILLER CONSTANT CHILLER FLOW It is important, for most chillers, that a fairly constant chiller Elow rate be established for good chiller load control. Unless precautions are taken chiller "short cycle” can occur with resulting chiller problems. Changing chiller flow rates will occur with 2 way valve system control. 2 war VALVES CHILLER CONTROL: Figure VI-1 - TWO WAY VALVE CONTROL CAUSES CHILLER FLOW CHANGE ‘The chiller control is tenperature sensitive only and will go into the sane load control regardless of flow rate. For a system design to full load at 300 GPM, the temperature control will load the chiller properly only at 300 GPM. At 100 GPM flow past the chiller control point, only 1/3 load is required for any given load temperature signal. The chiller control cannot recognize the change in load caused by flow change, however, and chiller load control is upset. The solution is to provide a relatively constant flow rate past the chiller temperature load registration point. This can be accomplished by either of two methods. 1. Separate chiller pump 2. Differential pressure controlled bypass valve. acircum mens PRESSURE oreaas 2 way Vvauwe conto. CHILLER LonD conTROL Figure VI-2 - DIFFERENTIAL PRESSURE CONTROL ‘ACROSS CHILLER OPENS BYPASS FOR CONSTANT CHILLER FLOM, In Figure VI-1, a constant chiller flow rate is established by differential pressure control activation of a two way bypass valve. pressure differential controller is set to maintain a relatively constant pressure drop (constant flow). The differential pressure control is often taken across a cali- brated orfice meter, rather than the chiller itself. The separate chiller pump is also employed chiller flow regardless of system flow change. IM DISTRIBUTION PUMP, RS COMMON FIPING BYPASS YS 2 way CHILLER RETURN: CHILLER DISCHARGE CONTROL ConsTANT Chiccer’ row CHILLER Loa CONTROL Rieut/ Figure VI-3. - CONSTANT CHTLLER FLOW ESTABLISHED BY_SEPARATE CHILEER PONP. to provide constant‘The separate chiller pump provides constant flow rate through the chiller regardless of system flow rate. When system flow rate reduces to less than chiller flow rate, bypass flow from chiller discharge to chiller return occurs through the common piping A mixture of system return with chiller discharge water occurs so that a true load statement is made to the chiller control device in terms of entering chiller temperature, ‘The separate chiller pump removes chiller P.D. from system pumping considerations. Removal of the chiller P,D. increases 2 way valve control effectiveness because of a reduction in the main distribution pump head. ‘The separately circulated chiller, with slight modification, per- mits use of the chiller to "cool down" hot distribution mains while controlling inlet chiller water temperatures. 2, Inmediate "cool down" of hot distribution main, Primary-Secondary-Separate Chiller Pump. A conmon operational problem with combination heating-cooling systems concerns switch over from heating to cooling when residual system water temperatures are too high (over 90°) to permit instant chiller start up. ‘The separately circulated chiller can be used to "cool down" the hot system water by mixing of chiller discharge water with main system water to provide allowable chiller entry temperatures. Either of two methods can be used: 1, Gonstant chiller flow; reduced main flow. 2. Constant chiller flow; constant system flow with controlled "bleed" flow. 19Teo Siig uncer uray Sinrer SamucTURE oF Rov arstem wins coun, Gucae otscungee) cutter Figure VI-4 - TIMED 3 WAY VALVE APPLIED TO SYSTEM COOL DOWN In this arrangement, often applied by Barber Colman, a three way valve is time cycled to open from full open bypass to bypass closed in about 20 Min. (time dependent on system water volume and temp.) SWOT" SYSTEM WATER, COLD DISCHARGE WaTHE Pigure VI-5 - THREE WAY VALVE, CONTROLLED FROM ‘SHILLER INLET TEMPERATURE In figure VI-5, the three way valve is set so as to open to bypass when inlet temperatures are over 90° and to close to bypass when inlet temperature is less then 80°, The three way would be controlled by master, sub naster controllers 50 arranged so as to decrease bypass flow and increase system "bleed" flow as system water temperature is decreased by chiller operation. When system water temperature is reduced to less than 80°, the valve closes completely to bypass and normal system operation occurs. Another, and very simple arrangement, makes use of a small change- over distribution pump applied in parallel with the main distribution pump.MAIN PUMP DISTRIBUTION MAIN DISTRIBUTION PUMP, CONTROL SorR"@ TEMP OVER 90% “on” @ TEMP UNDER 90° sveass over Sani cunnce ove CHILLER, IMP CONTROL OM AT ‘Tene over 30% 0F# at TENR UNDER 90! Figure VI-6 - CHANGEOVER PUMP; OPERATION CON- TROLLED FROM SYSTEM WATER TEMPERATURE The changeover punp illustration above will generally be a small booster pump providing a system flow rate less than chiller flow rate. Since system flow rate is less than chiller flow, a continuous bypass flow oceura in the Primary-Secondary bypass mixing with system water to provide mixed chiller entry water that is less than 90°. When system water temperature decreases to 90°, the main distri- bution pump is energized and normal system operation takes place. VII. EQUIPMENT ROOM PUMPING HEATING/COOLING 1, Standby Pump Provision Most Large heating-cooling systems have standby pump provision, A common standby method is illustrated below: Figure VII-1 - COMMON STANDBY; STANDBY SERVES BOTH TOWER AND SYSTEM DISTRIBUTION aO The common standby pump is selected to the greater flow requirement; usually tower pump and is checked against distribution head requirement by use of system curve analysis for actual standby system distribution flov. 2. Paralleled Chiller; Each Chiller with its own Pump On some larger systems, chillers are placed in parallel; each chiller having its own circulation pump, which is also applied to system distribution. As load increases chillers are placed on the line, as load decreases chillers and their pumps are cut off. CHMLER ‘CAUTION IN PUMP SELECTION 0 system system CHAR Figure VII-2 - PARALLEL CHILLERS; EACH CHILLER WITH PUMP Caution must be applied in pump selection and operation for this arrangement. The pump selection can be easily made for full load operation; with both ehillers and their pumps in operation. As an example: Pump selection is to be made for parallel chillers; each with its own pump. Bach chiller has 20 ft. P.D, at 200 GPM. ‘The piping system, ex- clusive of the chillers, has 80 ft. P.D. at 400 GPM. The selection point for each pump is then 100 £t. head at 200 GPM. A "system curve" can be struck for each pump using the "point" 100 ft. @ 200 GPM.TIL When only a single chiller is in operation, however, a new set of circumstances is faced by the single operating pump. The revised “system curve" for single pump operation can be developed by referencing piping system P.D. (P.D. exclusive of chiller) to single chiller flow and adding piping system P.D, and chiller P.D. at a common flow rate; usually design chiller flow rate, In this case: Reference to both Chillers; System Piping P.D. = 80' @ 400 G.P.M. Reference to single Chiller; System Piping P.D. = 20' @ 200 G.P.M. ‘The total revised system curve for the single pump and chiller will then be: Chiller P.D. = 20° @ 200 G.P.M. Piping P.D. = 20' @ 200 G.P.M, Total System = 40' @ 200 G.P.M. , A system curve developed through 40' @ 200 G.P.M, will yield re- quired information for operation of the single chiller. EQUIPMENT OR BOILER ROOM PRESSURIZATION PROBLEMS; HEATING AND/OR COOLING Note (to be added in Appendix) BFLUID HANDLING TRAINING & EDUCATION DEPT INTED IN UB, 968 Fr eUUis TRANSEen CIMISION