Belimo Aircontrols, Inc. (USA) : Basic Hydronic Training

Belimo Aircontrols, Inc.
(USA)
Basic Hydronic Training
BELIMO Aircontrols
Basic Hydronic Training 1
System Components
BELIMO Aircontrols
Components in a Hydronic System
6 7
2
3
4
BELIMO Aircontrols
Load
Source
1.
2.
3.
4.
5.
6.
7.
Pump
Load
Control Valve
Balancing Valve
Source
Air Removal System
Expansion Unit
Source Carrier Load

Water, Air, Refrigerant, Electricity
Heating
Cooling
BELIMO Aircontrols
Source
Load
Heating Load
Cooling Load
Hydronic Systems
Heating
Cooling
43F
57F
BELIMO Aircontrols
55F
250F
185F
240F
Heating Coil
Cooling Coil
Chiller
45F
Boiler
40F
245F
190F
Load
Source
Load
Source
Water Systems
Expansion
Chamber
Closed System
BELIMO Aircontrols
Open System
Closed Water Systems

Low Temperature Water (LTW)
- Max. 160PSI and max. 250F
Medium Temperature Water (MTW)
-Max. 160PSI / 250F to 350F
High Temperature Water (HTW)
-Max. 300 PSI and max. 350F
Chilled Water Systems (CWS)
- Max. 120 PSI / 40F to 55F (44F or 45F)
BELIMO Aircontrols
Piping Circuits
Two Pipe System

Three Pipe System
Four Pipe System
Direct and Reverse Return Systems
Primary-Secondary System
BELIMO Aircontrols
Two Pipe System
Main Supply Chilled Water or Heat Water

Supply one pipe, Return one pipe
Cooling or heating at source
Loads must all require cooling or heating
coincidentally
BELIMO Aircontrols
BELIMO Aircontrols
Load
Load
Load
Chiller
Boiler
Two Pipe System
Two Pipe System
BELIMO Aircontrols
BELIMO Aircontrols
Load
Load
Load
Chiller
Boiler
Three Pipe System
Three Pipe System
BELIMO Aircontrols
Three-Pipe System
BELIMO Aircontrols
Four Pipe System
BELIMO Aircontrols
Four Pipe System with One Coil
BELIMO Aircontrols
Four Pipe System with H&C Coil
BELIMO Aircontrols
Cost for Four Pipe System

High first cost due to the second water system and the
need for either two coils or more costly control valves
at each terminal unit.
High operating cost due to the two pumps operating,
but do provide good flexibility in meeting varying loads.
BELIMO Aircontrols
Advantages of Four Pipe Systems

All year availability of heating and cooling with individual
zone temperature control
Chilled and hot water are typically only simultaneously

supplied during the Spring and Fall seasons
Elimination of zoning cost and complexity
Simpler changeover decisions
The lowest and quietest fan speed is adequate most of
the time.
BELIMO Aircontrols
Piping - Direct Return Piping

Coil #4
0 - 100 gpm
Coil #3
0 - 100 gpm
Coil #2
0 - 100 gpm
Coil #1
0 - 100 gpm
Source
BELIMO Aircontrols
Piping - Reverse Return Piping

Coil #4
0 - 100 gpm
Coil #3
0 - 100 gpm
Coil #2
0 - 100 gpm
Coil #1
0 - 100 gpm
Source
BELIMO Aircontrols
BELIMO Aircontrols
Load
Load
Load
Source
Source
Source
Primary Secondary System
Pipe Design
BELIMO Aircontrols
Bernoullis Law
pstat
pdyn
const.
The Bernoullis law is stating the principle of

energy conservation. The sum of the two energies
represented by static pressure and dynamic
pressure is constant between two points in the
pipe, assuming no energy exchange with the
exterior or transformation of energy into heat by
friction between these two points.
BELIMO Aircontrols
Bernoullis Law
pdyn1
pdyn2
ptotal1
pstatic1
BELIMO Aircontrols
ptotal2
pstatic2
Z1
V12
2g
P1
Z2
V22
2g
P2
hL
V2 P2
hL
V1 P1
Z2
1
Z1
BELIMO Aircontrols
Pipe Sizing and Pressure Drop Equations

h
L
f
D
V2
2g
Darcy-Weisbach Equation
h pressure drop, in ft
f friction factor, dimensionl ess (from Moody )
L Length of pipe, ft
D Internal Diameter of pipe, in
V Fluid average velocity, ft/sec
g gravitatio nal constan, 32.2 ft/sec 2
BELIMO Aircontrols
Sizing a Piping System Pipe Friction Loss

Suggested head loss in range from 1 to 4ft per 100ft
- 1997 ASHRAE Handbook-Fundamentals
Max. 4 ft/sec velocity in pipe 2
Suggested 4 ft/sec velocity in pipes larger than 2
BELIMO Aircontrols
Simplified Method
D
S Q 0 .4
D = Pipe Diameter
Q = Flow Rate, GPM
S = Pipe Sizing Constant
- S= 0.44, assuming 4 ft head drop/100ft
- S = 0.5 assuming 2 ft head drop/ 100ft
BELIMO Aircontrols
Examples
Load: 100GPM
D = SQ0.4 = 0.44 x 1000.4 = 2.78 3
Load: 200GPM
D = SQ0.4 = 0.44 x 2000.4 = 3.66 4
Load: 300GPM
D = SQ0.4 = 0.44 x 3000.4 = 4.31 4
Load: 400GPM
D = SQ0.4 = 0.44 x 4000.4 = 4.83 5
BELIMO Aircontrols
Head Loss Calculation

Pipes (Friction Loss for Water in Commercial Steel Pipe
(Schedule 40)
Strainers, Fitting, Elbows, Reduction, etc
Valves, Balancing Valves (Valve - Manufacturer)
Head loss Load (Coil, etc.)

Head loss Source (Chiller, etc.)
=Total Head Loss

BELIMO Aircontrols
Head Loss in Pipes

Head Loss
Pipes (Friction Loss for Water in

Commercial Steel Pipe (Schedule 40)
Flow Rate
100GPM
2.5ft
BELIMO Aircontrols
hspec =ft/100ft pipe

Total h=L x hspec /100
Fittings
h
V2
k
2g
h = head loss in feet of water

k = resistance coefficient for valve or fitting
V2/2g = velocity head, ft based on flow gpm in connect pipe (example Figure
2 15 for 2 in)
V = fluid velocity, ft/sec
g = 32.2 ft/sec2, gravitational constant
BELIMO Aircontrols
BELIMO Aircontrols
GPM
GPM
BELIMO Aircontrols
Coil
Total Pipe length = 300 ft

BTU/HR = 500,000 BTU/HR
T = 10F
GPM = ?
Chiller
Which pump do we choose?
BTUH
T 500
BTUH
T 500
500000
100GPM
10x500
What is the pipe size?

Required Flow: 100GPM
Pipe Diameter: ?
D
S Q 0 .4
D = SQ0.4 = 0.44 x 1000.4 = 2.78 3
D = Pipe Diameter
Q = Flow Rate, GPM
S = Pipe Sizing Constant
S= 0.44, assuming 4 ft head loss/100ft
S = 0.5 assuming 2 ft head loss/ 100ft
BELIMO Aircontrols
Head loss elbows?
V2
k
2g
42
0.8
2 32.2
Coil
Chiller
Pipe: 3, Steel Pipe, screwed

Head loss of total elbows?
0.2 ft
4 Elbow 0.8ft
BELIMO Aircontrols
Head loss pipe?
Coil
Pipes (Friction Loss for Water in

Commercial Steel Pipe (Schedule 40)
Figure 2-14 Friction Loss - Water
Chiller
Pipe: 3, Steel Pipe, screwed

Total Pipe length = 300 ft
2.5 ft/100ft
h = 300 x 2.5 /100 = 7.5ft

BELIMO Aircontrols
Coil
1 Chiller 9 ft (4PSI, Info Manuf.)

1 Cooling Coil 9 ft (4PSI, Info Manuf.)
1 Control Valve 9 ft (4PSI)
1 Balance Valve 3 ft (1PSI)
4 Elbows each 0.2 ft 0.8 ft
1 Pipe System 7.5 ft
Chiller
Total head loss?
Total Head Loss of 38.3ft at 100GPM
BELIMO Aircontrols
System Curve
80
Head (ft)
60
System Point at
design load
40
20
10
Head Loss of 38.3 at 100GPM

0
20
40
60
80
100
120
140
160
180
200
Flow GPM
BELIMO Aircontrols
Pumps in HVAC
BELIMO Aircontrols
Pumps in HVAC
Pumps
Dynamic
Centrifugal
Volute Type
Single Suction
BELIMO Aircontrols
Special Effect
Displacement
Reciprocating
Rotary Pumps
Axial Flow Type
Double Suction
Outlet Flow
Impeller
Inlet
Flow
BELIMO Aircontrols
Blade
Pump Curve
Pump Characteristic
Coil
Chiller
Pump
Head
Operating Point
System
Head
V
100%
BELIMO Aircontrols
Volume
Pump Curve (Steep)
Pump Characteristic
Coil
Chiller
Operating Point
100%
BELIMO Aircontrols
Volume
Pump Curve (Flat)
Coil
Chiller
Pump Characteristic
Operating Point
25%
V
100%
Volume
BELIMO Aircontrols
Operating Point
Pump Head
Capacity Curve
Coil
Chiller
Operating Point
Load 100% Flow
100%
System Head
Curve
BELIMO Aircontrols
System Curves for a Pump Type

80
Head (ft)
60
40
7.0
70%65% 60% 55%
6.5
6.0
20
5.5
5.0
10
20
40
60
80
100
120
Flow GPM
BELIMO Aircontrols
140
160
180
200
Motor Horsepower
Minimum Flow of Pump

Depends on pump construction and energy generated
by pump
Not enough flow could result in overheating and
cavitation
Some low power pumps can operate at zero flow
Installation of bypass circuit
BELIMO Aircontrols
Valves in HVAC
BELIMO Aircontrols
What Control Characteristic is Preferred?

100
90
Heat Output
Heat Output (%)
80
70
60
50
40
30
20
10
10
20
30
40
50
60
70
80
90
100
Control Signal (%)
BELIMO Aircontrols
What are the Coil Characteristics?

100
90
Characteristic of
a coil
Heat Output (%)
Heat Output
80
70
60
50
40
30
20
10
10
20
30
40
50
60
70
80
90
100
Valve Opening (%)
BELIMO Aircontrols
What are the Valve Characteristics?

100
Heat Output
Flow, Heat Output (%)
Characteristic of
a Coil
90
80
70
60
50
Characteristic of
Control Valve
40
30
20
10
10
20
30
40
50
60
70
80
90
100
Signal (%)
BELIMO Aircontrols
Valve Characteristics
Modified Equal Percentage
100
Lift
Theoretical
Flow
Corrected
Flow
100
100
100
90
80
80
80
64
64
70
51
51
60
41
41
50
33
33
40
26
26
30
21
19.5
20
17
13
10
13.4
6.5
10.7
90
Flow (%)
80
70
60
50
40
30
Equal %
20
10.7
Linear Curve
10
10
20
30
40
50
60
70
80
90
100
Valve Opening (Signal) (%)

BELIMO Aircontrols
Valve Authority
BELIMO Aircontrols
Authority of Control Valves

with Variable Flow Through the Coil
Authority of two way control valves
Authority of three way control valves
BELIMO Aircontrols
3-way Control Valve

4
12
20 psi
Const
A
BELIMO Aircontrols
pv100
4
8
pv100
pFlowVariable
pv100
pv 0
0.5
3-way Control Valve

4
12
20 psi
Const
A
BELIMO Aircontrols
pv100
4
8
pv100
pFlowVariable
pv100
pv 0
0.5
3-way Control Valve

45
41
1214
50%
01
20 psi
Const
BELIMO Aircontrols
Valve Authority - Flow 100%
P Valve
P Terminal
Coil
P Terminal =const
BELIMO Aircontrols
P Valve
P Terminal
Coil
P Terminal =const
BELIMO Aircontrols
P Valve
P Terminal
Coil
P Terminal =const
BELIMO Aircontrols
2-way Control Valve

4
12
20 psi
VFD
A
BELIMO Aircontrols
pv100
4
20
pv100
pFlowVariable
pv100
pv 0
0.2
2-way Control Valve

41
416 123
50%
20 psi
VFD
BELIMO Aircontrols
BELIMO Aircontrols
P Valve
P Terminal
Coil
BELIMO Aircontrols
P Valve
P Terminal
Coil
P Valve
P Terminal
Coil
P Terminal =const
BELIMO Aircontrols
Sizing Rules
Authority = 0.4 to 0.5

Min. pvalve = 0.25 p pumphead
BELIMO Aircontrols
Authority Distortion of Linear Flow

Characteristics
100
90
Flow (%)
80
0.1
70
0.2
0.4
60
0.6
0.8
50
1
40
30
20
10
10
20
30
40
50
60
70
80
90
100
Valve Opening (%)

BELIMO Aircontrols
Authority Distortion of Equal Percentage

Flow Characteristics
100
90
80
Flow (%)
70
60
0.1
50
0.2
40
0.4
0.6
30
0.8
1
20
10
10
20
30
40
50
60
70
80
90
100
Valve Opening (%)

BELIMO Aircontrols
Counter-Flow
Cross-Flow
Parallel-Flow
Counter-flow, cross-flow or parallel-flow heat exchangers are used

depending on the application. They have different efficiencies.
BELIMO Aircontrols
Constant or Variable Flow

e.g. air
Regardless of valve position, the

full water flow is always circulating
through the heat exchanger
=> Temperature control
Depending of valve position,

0..100% of the water flow
circulates through the heat
exchanger
=> Flow control
BELIMO Aircontrols
Constant or Variable Flow

Prevention of
freezing
yes
no
Large outside flow?
no
no
yes
Are different temperature

levels in coil acceptable?
no
Temperature control
constant Flow
Variable temperature
BELIMO Aircontrols
yes
Dehumidification
yes
yes
Flow Control
Constant Temperature
Variable Flow
Diverting Circuit with Mixing Valve

pFV
Coil
var
var
var
pV100
100%
BELIMO Aircontrols
100%
Diverting Circuit with Diverting Valve

pFV
Coil
var
var
var
pV100
100%
BELIMO Aircontrols
100%
Throttling Circuit
pFV
Coil
var
var
pV100
BELIMO Aircontrols
Mixing Circuit with Mixing Valve

Coil
100%
100%
var
p v100
var
BELIMO Aircontrols
var
Heat Exchanger Characteristics

100
0.05
90
0.15
Energy (%)
80
0.25
0.4
0.6
0.8
1
70
60
1.5
2
50
40
30
20
10
10
20
30
40
50
60
70
80
90
Application
a-Value
Pre Heating
Coil
Heating Coil
0.25 to 0.4
Cooling Coil
0.25 to 0.5
Radiators
0.5 to 0.65
Converters
0.5 3.0
0.15 to 0.4
100
Flow (%)
BELIMO Aircontrols

100
90
Variable Flow
Energy (%)
80
70
Constant Flow
60
50
40
30
20
10
10
20
30
40
50
60
70
80
90
100
Flow (%)
BELIMO Aircontrols

100
90
T = 10F
Energy (%)
80
70
T = 30F
60
50
40
30
20
10
10
20
30
40
50
60
70
80
90
100
Flow (%)
BELIMO Aircontrols

100
90
Heating Coil
Energy (%)
80
70
Cooling Coil
60
50
40
30
20
10
10
20
30
40
50
60
70
80
90
100
Flow (%)
BELIMO Aircontrols
Influencing Factors
Valve with
Hydraulics
Base Valve
Characteristic
BELIMO Aircontrols
Hydraulic
System
Heat
Exchanger
System Valve
Coil
Characteristic Characteristic
Resulting
Characteristic
Conventional Sizing Methods
BELIMO Aircontrols
Application
Pressure Differential Sensor
Coil #4
0 - 100 gpm
10 psi
p=2 psi
p=12 psi
p=22 psi
20 psi
p =4 psi
p=4 psi
Coil #2
0 - 100 gpm
30 psi
p =4 psi
p=4 psi
Coil #3
0 - 100 gpm
20 psi
10 psi
30 psi
p=4 psi
p=4 psi
40 psi
Coil #1
0 - 100 gpm
40 psi
p=32 psi
p=4 psi
p=4 psi
Chiller
VFD-Pump
BELIMO Aircontrols
Application
Authority
Coil #4
0 - 100 gpm
p=2 psi
p=12 psi
p=22 psi
p =4 psi
p=4 psi
Coil #2
0 - 100 gpm
30 psi
p =4 psi
p=4 psi
Coil #3
0 - 100 gpm
20 psi
A=4/10=0.4
p=4 psi
p=4 psi
Flow/Heat output %
10 psi
A=4/20=0.2
A=4/30=0.14
Coil #1
0 - 100 gpm
40 psi
p=32 psi
p=4 psi
Chiller
A=4/40=0.1
p=4 psi
Signal
VFD-Pump
BELIMO Aircontrols
Shift to Variable Supply with VFD-Pumps

and Two-way Valves 4
4
12
20 psi
Const
12
20 psi
VFD
BELIMO Aircontrols
Authority Method
BELIMO Aircontrols
Application
Coil #1
0 - 100 gpm
10 psi
p=2 psi
p=4 psi
Coil #2
0 - 100 gpm
20 psi
p=6 psi
p=11 psi
p =10psi
A=0.5
A=0.5
p=4 psi
Coil #3
0 - 100 gpm
30 psi
p =4 psi
Flow/Heatoutput
p=15 psi
A=0.5
p=20 psi
A=0.5
p=4 psi
Coil #4
0 - 100 gpm
40 psi
p=16 psi
p=4 psi
Chiller
Signal
VFD-Pump
BELIMO Aircontrols
Current Concepts for Valve Sizing

Exact
calculation
f( p and V)
Rule:
pvalve = pCoil
Rule:
pvalve= 3 5 psi
BELIMO Aircontrols
Correct sized components

Generally less expensive components, like valves
Complex procedures for all involved
More detailed information is required
Consideration of diversity factors
No feedback of sized devices from suppliers
Very simple rule

Used by all involved in the project
Good base for price comparison
Oversized valves overpriced valves
Bad authority
Hunting
Instable control loops
Additional Valve Sizing Considerations

Two-way valves:
For the close-off pressure the pump
head needs to be considered.
Three-way valves:
Pressure difference valve
For the selection of the valve bodies it is

necessary to consider elevation of
system, pump pressure and fill pressure
BELIMO Aircontrols
Reference Literature
Total Hydronic Balancing
Robert Petitjean, Tour & Andersson Hydronic AB
HVAC Pump Handbook
James B. Rishel, McGraw-Hill
ASHRAE Handbooks
HVAC Equations, Data, and Rules of Thumb
Bell, McGraw-Hill
BELIMO Aircontrols
Thank You
BELIMO Aircontrols

Belimo Aircontrols, Inc. (USA) : Basic Hydronic Training

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Belimo Aircontrols, Inc.

Basic Hydronic Training

Basic Hydronic Training 1

Basic Hydronic Training 2

Components in a Hydronic System

Basic Hydronic Training 3

Source Carrier Load

Basic Hydronic Training 4

Basic Hydronic Training 5

Closed Water Systems

Basic Hydronic Training 7

Two Pipe System

Basic Hydronic Training 8

Two Pipe System

Main Supply Chilled Water or Heat Water

Basic Hydronic Training 9

Two Pipe System

Basic Hydronic Training 10

Two Pipe System

Basic Hydronic Training 11

Three Pipe System

Basic Hydronic Training 12

Three Pipe System

Basic Hydronic Training 13

Basic Hydronic Training 14

Four Pipe System

Basic Hydronic Training 15

Four Pipe System with One Coil

Basic Hydronic Training 16

Four Pipe System with H&C Coil

Basic Hydronic Training 17

Cost for Four Pipe System

Basic Hydronic Training 18

Advantages of Four Pipe Systems

Chilled and hot water are typically only simultaneously

Basic Hydronic Training 19

Piping - Direct Return Piping

Basic Hydronic Training 20

Piping - Reverse Return Piping

Basic Hydronic Training 21

Primary Secondary System

Basic Hydronic Training 22

Basic Hydronic Training 23

The Bernoullis law is stating the principle of

Basic Hydronic Training 24

Basic Hydronic Training 25

Basic Hydronic Training 26

Pipe Sizing and Pressure Drop Equations

Basic Hydronic Training 27

Sizing a Piping System Pipe Friction Loss

Basic Hydronic Training 28

Basic Hydronic Training 29

Basic Hydronic Training 30

Head Loss Calculation

Head loss Load (Coil, etc.)

=Total Head Loss

Basic Hydronic Training 31

Head Loss in Pipes

Pipes (Friction Loss for Water in

hspec =ft/100ft pipe

Basic Hydronic Training 32

h = head loss in feet of water

Basic Hydronic Training 33