There are two main types of heating systems - open vented systems and sealed systems. Open vented systems are the most common and use an open vent pipe and feed and expansion cistern to accommodate water expansion. Sealed systems use an expansion vessel instead of a cistern. Identifying the index circuit, which has the highest resistance, is important for correctly sizing the circulating pump to ensure adequate water flow throughout the entire system.
Original Description:
This presentation gives an overview of industrial and commercial heating system installation.
There are two main types of heating systems - open vented systems and sealed systems. Open vented systems are the most common and use an open vent pipe and feed and expansion cistern to accommodate water expansion. Sealed systems use an expansion vessel instead of a cistern. Identifying the index circuit, which has the highest resistance, is important for correctly sizing the circulating pump to ensure adequate water flow throughout the entire system.
There are two main types of heating systems - open vented systems and sealed systems. Open vented systems are the most common and use an open vent pipe and feed and expansion cistern to accommodate water expansion. Sealed systems use an expansion vessel instead of a cistern. Identifying the index circuit, which has the highest resistance, is important for correctly sizing the circulating pump to ensure adequate water flow throughout the entire system.
Description A basic description of heating system installations
Author Mrennan !rganisation "esearch Machines plc# HEATING SYSTEM DESIGN There are many diferent wet system designs; they can be grouped into two main categories, either; - Open Vented Systems - Sealed Systems There are also many diferent types of system pipe design to be considered such as; - Two-pipe - Single-pipe - Gravity - Microbore Open Vent Systems This is the most common type of system that has been installed over recent years within the Industry. It is called Open due to the fact that the water circulated through the system radiators and cylinder calori!er is open to atmosphere using an open safety vent pipe. The e"pansion and contraction of this water due to heating and cooling is accommodated by a feed and e"pansion cistern, and water is supplied to the system by the use of a #eed and $"pansion pipe %cold feed&. Open Safety Vent pipe The 'ent pipe is a safety device installed to the (entral )eating *ystem. It enables any steam or high temperature water to be removed from the heat e"changer in the event of boiler controls failure. The 'ent pipe is generally installed to the main )eating +ow, or directly to the boiler. The pipe should rise continuously to discharge above the #eed and $"pansion cistern. There should be no valves installed, either manual or automatic in the route of the vent pipe. ,ith the introduction of more powerful pumps, and the increase in resistance in central heating circuits, due to high resistance boilers and radiators, the correct positioning of the vent pipe is essential. It is important to avoid pressures below atmospheric which may draw in air through the open vent pipe, or small lea-s within the system, such as through valve pac-ing which may be watertight but not airtight. It is also important to avoid a rise in water level in the vent pipe such that water is forced over into the feed and e"pansion cistern thus aerating the water in the system. The ingress of air will eventually cause the corrosion process to accelerate, leading to sludge being formed and subse.uent bloc-ages and restrictions within the system or corrosion of heat emitters. Feed and Expansion Pipe (Cod Feed ! This describes the dual functions of this pipe are to feed water down into the system to permit water on heating up, to e"pand into the cistern above. 'ery often this pipe is referred to as the cold feed pipe, even in some /ritish *tandards. This is a poor description as its main function is to handle the e"pansion of heated water within a system. Its main tas- is to deal, therefore, with the results of heat being applied to water. It also has to assist the safety vent pipe in the event of overheats within the heat e"changer. In such situations it is vitally important for the feed and e"pansion pipe to -eep the boiler full of water. (ommonly a 0oc-shield gate valve is installed, generally found at the connection to the heating system on the return pipewor- within the boilerhouse plantroom. Feed and Expansion Ciste"n This cistern is connected to the mains water supply through a ball operated +oat valve and replenishes a system with water after installation or remedial wor- being carried out. 1nother important function of the cistern is to accept the e"panded heated water within the system. It is one of the most neglected and yet one of the most important pieces of e.uipment in the system. The common components found with the cistern are the Open *afety 'ent 2ipe, /all operated +oat valve, #eed and $"pansion pipe, and an Over+ow ,arning pipe. Seaed Systems The *ealed system is not open to the atmosphere and incorporates a sealed e"pansion vessel which replaces the feed and e"pansion cistern of the open vent system. $"pansion and contraction of the system water is accommodated within this vessel. 1 pressure relief valve is installed as a safety feature similar to a open safety vent pipe. The system provides a number of bene!ts; - The system is sealed to atmosphere, therefore corrosion is reduced within the installation - System can run at a higher temperature than an open system - No feed and epansion cistern is re!uired In the open system the feed and vent arrangement protects the system in the event of boiler failure. The sealed system is protected by an overheat thermostat on the boiler and a separate pressure relief valve. Only boilers speci!cally intended for use with a sealed system should be installed, these will contain an appropriate high temperature cut3out as standard Expansion Vesse The e"pansion vessel should be !tted on the suction side of the pump. The point at which it is !tted becomes the neutral point of the system. The e"pansion vessel is divided into two compartments and separated by a +e"ible diaphragm. The sealed side is charged with nitrogen gas or air. The open side is connected to the system. 1s the water is heated it e"pands and compresses the nitrogenair until the e"pansion is accommodated within the e"pansion vessel. The diagrams above indicate the e"pansion vessel in a cold state %1& when the temperature increases %/& and !nally when at system operating temperature %(&. 1t this point the pressure in the system has risen due to the e"pansion of the system water, compressing the gasair until full e"pansion has ta-en place, at this point the diaphragm will become virtually static, with increased pressure, but e.ual on both sides of the diaphragm. P"ess#"e $eief Va%e 1 safety pressure relief valve must be !tted either on the appliance or on the +ow pipe. The safety valve must open when the system pressure increases above the set system pressure and discharge in a safe manner. There should be a discharge pipe to low level in the boilerhouse plantroom, and on combination boilers the discharge will be to a safe position outside the property. The discharge pipe should always terminate in a downward direction to avoid ris-s to people in the area. 2ressure relief valves are often used to drain the system or areas in the plantroom, this is a practice not recommended, as the seating of the valve can become contaminated with any debris from within the system. P"ess#"e Ga#&e 1 pressure gauge recording the pressure of the system is re.uired to enable the system to be charged from cold to its design pressure. This gauge is also useful when establishing whether the system is losing pressure, therefore indicating a water lea-. Ci"'#atin& P#mp In modern systems, the pump provides the motive force behind the circulation of water within the heating system. The position of the pump is crucial to whether the system operates under negative or positive pressure. In open systems the pump is installed on the +ow pipe, either after the open vent pipe and cold feed or where the open vent and cold feed are connected to the boiler, the pump would be installed on the +ow pipe from the boiler. This allows the system to operate under positive pressure. The pump head is also a most important factor in the design of an open central heating system. 2umps are ad4ustable having generally the option of difering speed settings and controls which enables the installer to ad4ust and vary the delivery of the head of water within the system. The pump will re.uire ad4usting to provide su5cient pressure and +ow rate to the inde" radiator to achieve the re.uired temperature diferential across the +ow and return connections of the radiator. This is achieved by the altering the pump speed. ,hen a system is being commissioned the pump speed is set to give the correct pressure %head& and +ow rate of water. 6omestic 2umps usually have several speeds %often 7 speeds& and can easily be set by a controller attached to the motor. 'ariable speed drives are used for larger 73phase electric motor driven pumps. Index Ci"'#it and (aan'in& t)e System The resistance within the +ow pipe to each heat emitter will vary depending on the length and route of the pipe design. The radiator with the greatest resistance will normally be the furthest from the boiler, although on some modern installations circuits of less length have more resistance due to a greater number of pipe runs and emitters. The radiator when established id therefore -nown as the inde" radiator. The radiator should be balanced at the loc-shield valve on the return connection of the heat emitter to achieve an appro"imate 889( drop in temperature between the +ow and return connections. 1ll other radiators on the circuit will have less resistance than the inde" radiator. This means that additional resistance has to be created by ad4usting the loc-shield valves on the emitters to gain the re.uired temperature drop between the connections. If no attempt is made to balance the system, poor performance can result as the heated water will only circulate through the circuit with the lowest resistance. This may lead to the emitters at the end of the circuit not reaching the desired temperature. The Inde" (ircuit needs to be identi!ed so that the pump can be si:ed. "ample # The system shown below is divided into two sub3circuits 1 ; /. 1 pipe si:ing calculation would determine which of the two sub3circuits had the most resistance and therefore which was the Inde" (ircuit. The reason for $nding the %nde &ircuit is to si'e the pump( The pressure developed by the pump should be capable of overcoming the resistance in the Inde" (ircuit. If the pump pressure can overcome the resistance in the Inde" (ircuit, then it can overcome the resistance in other circuits of lesser resistance. If it was found that the Inde" (ircuit was (ircuit %/& in the above diagram then we would include the +ow of water through radiators <o. 7, = and >. If we e"amine (ircuit %/& then the Inde" (ircuit +ows past ?adiator <o.7 and <o.= and through ?adiator <o.>. This would be the circuit with the highest resistance. If the pump is capable of forcing water through the pipewor- to ?adiator <o.> then there will be enough pressure to force the water through ?adiators <o.7 ; <o.= since they are closer to the pump. This is the reason why only one radiator is included in the calculations for resistance in the Pump Sub-Circuit B Sub-Circuit A BOILER No.1 No.2 No.3 No.4 No.5 Heat Emitters Inde" (ircuit. Si*in& of Expansion Vesse *i:ing of the $"pansion vessel essential, the vessel must be large enough to accommodate all the e"pansion of the water. The following information is re.uired to enable the correct si:e of vessel to be calculated; - The volume of water within the system( Manufacturers supply data includes water capacities of components such as boilers and heat emitters( - %nitial pressure of the system, calculated from the static height, which is the vertical distance from the epansion vessel to the highest point of the system( - The boiler )ow temperature Pump Sub-Circuit B is Index Circuit Sub-Circuit A BOILER No.1 No.2 No.3 No.4 No.5 Heat Emitters Radiator No.5 Included in Inde !ircuit capacities of expansion vessel Typical volumes of water contained within systems are as follows; &ast iron heat echangers #* litres +ow water content heat echangers ,(- litres Small bore pipewor. # litre/.w of system output Microbore system 0 litres Steel radiators 1 litres/.w of system output 2ot water cylinder/calori$er 3 litres The volume found from the previous table shall be multiplied by the appropriate factor from the table below; Maimum boiler )ow temperature 4actor 5,6& or greater #(* +ess than 5,6& but not less than 116& *(5 +ess than 116& *(1 Fiin& t)e Seaed System 2rovision must be made for !llingpressurising the system. The connection for the !lling a sealed system shall include a stop valve and double chec- valve assembly to prevent water from passing bac- into the mains water supply. 1 typical method would incorporate; - 7 temporary hose connection to the mains water - 7 stop valve should be installed to the service main outlet - 7 double chec. valve and stop valve should be installed to the system connection of the temporary hose Where an approved flling loop is used, which incorporates all necessary valves; it must be in accordance with manufacturers instructions. P"ess#"isation +nit 1nother method commonly used to pressure a sealed heating system is with the use of a 2ressurisation unit, which is sealed to atmosphere therefore the term sealed. 1 pressure sensor is !tted into the system as indicated in the diagram. If the pressure falls below a set pressure, a pump is operated which feeds mains water into the system pipewor-. ,hen the boiler increases in temperature, the pressure will also increase due to the e"pansion of water. This increased water volume is accommodated within the e"pansion vessel. In the event of a boiler control fault or the pressure increase being too great, the interloc- between the pressurisation unit and the boilers will switch the boilers of until the fault is recti!ed. $"cess pressure is released through a pressure relief valve. (ontinuous !lling of the system by the pump would indicate a lea- in the system. 1s well as -eeping the system water levels maintained .The 2ressurisation unit can also pressurise the water in the system. The bene!t of this is that the boiler +ow temperatures can be increased above 8@@9( without it boiling. This means the same volume of water will carry more energy to the heat emitters and smaller diameter pipewor- may be used which are easier to accommodate within pipe runs. T,o-Pipe System The preferred method of installing the heating circuit is to use two pipes, one pipe being the +ow from the heat source %boiler&, and the other being the return to the heat source. The main advantage is that appro"imately the same +ow temperature is available to each radiator, thus allowing the correct si:e radiator to be selected in the initial design of the system. 1 total heating system in a property, may be made up of a number of diferent designs of two3pipe systems serving various numbers of heat emitters. $ach emitter being supplied by the )eating +ow and return. Sin&e Pipe System The single pipe design of water supply to heat emitters is by far the simplest installed, using one pipe to supply all radiators on the circuit with heated water. 2ipe si:es and heat emitter si:es are generally larger to overcome resistance and meet output demands of the system. 1 disadvantage of this type of design is that the same +ow and return temperatures at the heat emitters cannot be maintained due to the cooling of the heated water as it circulates through the system. The reduction in temperature at the +ow and return connections to the heat emitters through a single pipe system is not desired, with reference to the diagrams attached. The !rst radiator %1& will receive water at the boiler output mean temperature at the +ow connection and after circulation through the radiator, the water will lose temperature due to some of the heat being e"tracted for the re.uired output of the radiator. The water is then circulated through the return connection of the radiator at a lower temperature bac- to the single pipe which has bypassed the radiator to ultimately mi" at a lower temperature than the boiler output mean temperature. This water is then circulated further to radiator %/& where the process continues. G"a%ity Ci"'#ation 1 Aravity central heating system depends on the diference in density of hot and cold water. (old water is heavier than hot water and, therefore, the cold water will drop and the hot water will rise. These types of systems were initially the only types used, until through the years they were gradually modernised by the further installation of controls and components. This type of system comprises of a heat source %boiler& installed to a system of pipewor-, which in turn circulates the heated water through the system to the radiators and calori!ers. ,hen the boiler is raised to temperature this allows the heavier cold water to fall through the return pipe and return to the boiler to be reheated, thus in turn displacing hot water within the boiler into the system and repeating the process. F#y P#mped Heatin& and Domesti' Hot .ate" System Bodern practice is to use a positive form of circulation, for both )eating and )ot water, this removes the reliance on gravity as the main form of circulation along with all its inherent disadvantages. 2umped circulation, to both heating and hot water, allows for smaller diameter pipewor- and a more +e"ible approach to the routes of pipes and in general a cost efective and e5cient installation. The use of the pump, to serve both the main )eating circuit and the )ot water circuit %primary&, allows the independent control of both domestic hot water and heating. The other advantage being speed of recovery and the control of temperature within the system. Instaation Fa'to"s The installation of a fully pumped system, is dependant on a number of important factors; - 8ump position - 8ump head - Open vent and &old feed position - &orrect pipe si'e - 8ipe layout - The pressure within a system, both negative and positive being correctly understood - The correct installation of controls - 9etermining the :inde radiator; on the circuit - Balancing of the system
(oie"s ,hen the total heat re.uirements of the system have been calculated, the installer will need to select a boiler to meet both the system and client re.uirements. 1 number of considerations must be made before the selection of the boiler such as; - +ocation - <oiler heat output - &lients speci$c re!uirements - 8hysical si'e of boiler - 4uture design plans of the system and to the total heating re!uirements - Type and &ompatibility - Type of fuel supply )aving considered all of the above then the selection of the boiler can be !nalised, the boiler should be matched to the total calculated hot water and heating. It is normal to select a boiler of a larger output in the event of the system being e"tended in the future. Cltimately the boiler will be either Open3+ued or ?oom3sealed.