CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

How to select size of

products and components.
Thermostatic valves.
Choice of valve size.
By-pass insert
Existing one-pipe systems.
All the radiators must be equipped with thermostatic valves to be able to
control the room temperature, use the incidental heat gain efficiently and
distribute the heat according to requirements. This requires a by-pass at
each radiator, and the resistance in the by-pass has to be larger than in
the main pipe so that a certain amount of water is let to in the radiator.
Good operation is obtained if the thermostatic valve has a low resistance,
like valves intended for gravity circulation, and the by-pass is of the same Existing one-pipe system with thermostatic valve
dimension as the main pipe. The by-pass is equipped with a restriction and by-pass.
creating the required resistance. Distribution through radiator and by-pass.
Fig. 7:1
Two-pipe systems.
The valve size is determined on the basis of the required flow and the
available differential pressure. Maximum differential pressure is limited
to 25 kPa as far as noise is concerned. The available differential pressure
for each thermostatic valve is obtained from the pipe calculation.

Flow.
The flow is calculated from the heat requirement in watts, W, and the
temperature drop across the radiator in Kelvin, K. The valve size can then
either be determined from a selection flow chart or be calculated.

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Valve size.
The last valve in the design circuit, (which determines the pump head
throughout the entire system) ought to have a resistance of about 5 kPa.
The other valves should be sized according to the differential pressure
available for them, i.e. the penultimate valve in the design circuit has an
available pressure equal to the resistance across the last valve plus the
resistance in the pipes between the two valves.

∆p 5 kPa
1

∆p 80 kPa
140 133 125 7

∆p 72 kPa ∆p 9 kPa

Available ∆p for the risers in a two-pipe system.

Fig. 7:2

RTD-N 15
l/h kvs -value Pre-set value l/s
500
,1
300 N ,07
200 7 6 ,05
1 7
100 5 ,03
4
70 0,60 0,45 ,02
50 3
0,36 0,27 2 ,01
kv 30
1 2 3 4 5 6 7 N 0,20 0,12 ,007
20 ,005
RTD-N 15 0,04 0,08 0,12 0,20 0,27 0,36 0,45 0,60 1
RTD-N 20 0,10 0,15 0,17 0,25 0,32 0,41 0,62 0,83
RTD-N 25 0,10 0,15 0,17 0,25 0,32 0,41 0,62 0,83 10 0,08 ,003
7 0,04 ,002
5
Radiator l/h ∆p kPa Pre-set ,001
1 140 5 N 3
1 2 3 4 5 7 10 20 30 kPa
∆pvalve

7 140 9 7
0,1 0,2 ,3 ,4 ,5 ,7 1 2 3 mWG
125 140 72* 3,5
0,01 ,02 ,04 ,06 0,1 ,2 ,3 Bar
140 140 80* 3,5
*too high ∆p, will create a problem with noise. Finding the pre-set values for the thermostatic valves in the above heating system.
Fig. 7:3

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Pre-setting.
Adjusting a valve implies a calculation of the difference between the
available and the required pressure for the valve. The resistance across the
valve should then be increased, through adjustment, so that all the
available pressure is utilized. The setting values providing the required
resistance can be read from the selection flow charts.The values for each
valve should be stated on the drawing so that the setting can be made in
connection with the installation.

Choice of control unit.

There are many conditions influencing the function of the thermostatic
valve. The control unit has to sense the room temperature to be able to
control it.This is not possible if it is covered by a long curtain or a
cabinet.
Heat radiation from warmer surfaces, for example heating pipes, a warm
floor, electrical devices etc., deceives the sensor into believe that it is
warmer than it actually is in the room.
Downdraught and draught from open windows or doors deceives the
sensor into believe that it is colder in the room than it actually is.
A control unit with a built-in sensor has difficulties in managing these
problems. A control unit with a separate capillary tube connected sensor
therefore should be chosen. The sensor can then be placed where it
detects the right room temperature.

The control unit has to sense the room temperature to be able to control it.
Fig. 7:4

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Control valves.
Primary systems.
Two-way valves and consequently varying flow are recommended for the
primary systems.

Available differential pressure.

A resistance of 100-120 kPa is recommended to be available in the
design circuit for the control valve.
As regards other control valves in systems without a pressure controlled
pump the available differential pressure is obtained from the pipe
calculation.
When using pressure controlled pumps with the sensor located farthest
away in the system all the control valves should be sized for the lowest
available differential pressure of the system. In other words, the differential
pressure set on the sensor, 150kPa, is recommended, minus the resistance
in the heat exchanger in question, 20-50 kPa. Check the resistance in the
heat exchanger with the supplier!
If the available differential pressure at a valve should increase by 50% or
more of the designed differential pressure a differential pressure control
is recommended for that particular valve. The designed differential pres-
sure is shared between the control valve and the differential pressure
control.

∆ppump
∆pmin
∆p ∆psystem
600 Min ∆p = 150 kPa 100
Flow %

500
400 50
300
200
0
100
0

If the pump is equipped with pressure control the valves must be calculated for the
lowest available ∆p. In this case 150 kPa, 1,5 bar, minus the resistance in the heat
exchanger.
Fig. 7:5

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Valve size.
Enter information of flow and available differential pressure into the
valve selection flow chart and then select the valve size! The dimension
of the pipe in which the control valve is to be installed has no influence
on the required valve size.

m3/h Valve kvs - value l/s

50 40 15
3 25 10
30 1 Example, control valve:
7
20 16 ∆t = 50 oC.
5 1 P = 1.500 kW; Q = 1.500 × 0,86 / 50 = 25,8 m3/h.
10 3
10
7 6,3 2 ∆p available = 1,5 bar. ∆p heat exchanger = 0,3 bar.
5 4,0
1,0 2 ∆p = 1,5 bar - 0,3 = 1,2 bar.
3 2,5 0,7
2 1,6 0,5 Values from diagram:
1,0 1,0 0,3 3 kvs = 25 m3/h, ∆pv = 1,1 bar
0,7 ,63 0,2
0,5 ,4
0,3 0,1
,07
0,2 ,05
2
0,1 ,03
10 20 30 40 60 100 150 kPa
∆pvalve

1 2 3 4 5 7 10 15 20 mWG
0,1 ,2 ,3 ,4 ,5 ,7 1,0 1,5 2 Bar

Sizing of the control valves in the adjoining district heating circuit.

Fig. 7:6

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Secondary systems.
Two-way valves should also be used in the secondary systems, with a
main pump supplying the water out to each mixing loop or shunt.

Available differential pressure.

Two-way valve.
A resistance of 10-15 kPa is recommended to be available for the control
valve in the design circuit.
The available differential pressure for other control valves in systems
without a pressure controlled pump is obtained from the pipe calculation
and as much as possible of the differential pressure should be used.

∆ppump
1 2 3 4 5 6 7 8 9

∆pvalve
∆psystem < 15 kPa

∆psystem ∆p 100% flow Design ∆p

without pump control or with constant ∆p
∆p kPa

60
50 ∆p at 0% flow
40 with max ∆p
30
20 with proportional ∆p
10
0
∆pvalve
With proportional or parallel pump control

Available ∆p with or without pump control at different flow.

Impulse tube
Fig.7:7
With regard to the pressure controlled pump with the sensor at the
pump, all the control valves should be sized for the lowest differential
pressure they will obtain. The designed differential pressure depends on
which type of pressure control that is used:
• a constant differential pressure gives design values according to the
pipe calculation
• a proportional control gives that design value which is 50% of the
maximum differential pressure
• a pressure control parallel to the pipe resistance gives a design value
that is 50% of the maximum differential pressure

This combination provides the control valve with the • a constant ∆p at control valve located the farthest away gives design
same available pressure when the flow fluctuates. values for all the control valves equal to the lowest set differential pres-
Fig 7:8 sure

144 8 STEPS - CONTROL OF HEATING SYSTEMS

 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

If the available differential pressure at a valve should increase by 50% or

more of the designed differential pressure, a differential pressure control
is recommended for that particular valve. The designed differential pres-
sure is shared between the control valve and the differential pressure
control.

Valve size.
Enter information of flow and available differential pressure into the
valve selection flow chart and then select valve size! The dimensions of
the pipe in which the control valve is to be installed has no influence on
the required valve size.

Sizing of the control valves in the above heating circuit. Exampel.

Q = 3 m3/h
∆ppump = constant
m3/h Valve kvs - value l/s ∆pavailable = from the calculation of the design
circuit, including valve 9.
200 50 Here: from the above diagram + ∆p valve no 9.
145 100 Excessive ∆p, ∆pexc. = ∆pavailable - ∆pvalve
100 30
∆ppump = ∆psystem + ∆p valve 9.
63 20
∆psystem = 60 kPa.
50
40 Sizing of control valve 9.
30 10
25 7 See diagram: 3 m3/h, ∆p<15 kPa
20 16 5 kvs 10, ∆p valve 9 = 9 kPa.
10 Selecting valve size from diagram:
10 3
Valve ∆pavailable kvs ∆pvalve ∆pvalve
7 3 1 6,3 2
5 1 53+9=62 4,0 55 7
9 8 7 6 54 2 4,0 1,0 2 47+9=56 4,0 55 1
3 2,5 0,7 3 40+9=49 6,3 23 26
2 1,6 0,5 4 34+9=43 6,3 23 20
1,0 1,0 0,3 5 26+9=35 6,3 23 12
0,7 ,63 0,2 6 20+9=29 6,3 23 6
0,5 7 14+9=23 6,3 23 -
,4
0,1 8 7+9=16 10 9 7
0,3
,07
0,2 ,05

0,1 ,03
1 2 3 4 5 7 10 20 30 40 60 100 150 200 kPa
∆pvalve

0,1 0,2 ,3 ,4 ,5 ,7 1 2 3 4 5 7 10 15 20 mWG

0,01 ,02 ,04 ,06 0,1 ,2 ,3 ,4 ,5 ,7 1,0 1,5 2 Bar

Sizing valves from a diagram will not give the same mathematical accuracy
as a calculation, but it is good enough when considering the inaccuracy of the
underlying calculations.
Fig 7:9

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Differential pressure controls.

∆p Only the differential pressure control can eliminate the pressure varia-
tions being the result of a varying flow in the systems, and only the dif-
ferential pressure control can provide the control valves with good
working conditions.
The valve size is determined on the basis of the required flow and the
available differential pressure. A differential pressure control keeping the
pressure constant across a control valve has to be sized along with the
control valve.
h
Controlled ∆p gives the best result. Primary systems.
Fig.7:10 Differential pressure controls are used in primary systems to keep the dif-
ferential pressure constant across a sub-station or a valve in the sub-
station.

Available differential pressure.

The available differential pressure for the sub-station, 150 kPa, minus the
resistance across the heat exchanger, 30 kPa, is the available differential
pressure for both the control valve and the differential pressure control,
∆pv2 =150-30=120kPa.

Two parallel connected heat exchangers.

Fig. 7:11

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Valve size.

Divide ∆pv2 by two and choose a control valve from the valve selection
flow chart according to the ∆p and the flow in question. The remaining
∆p, i.e.120 kPa minus ∆pv is the available differential pressure for the
differential pressure control. Enter the differential pressure and the flow
for the differential pressure control into the selection flow chart and
then select size!

∆ppump

∆psystem ∆pmin
∆p
600 Flow % 100
500
400 50
300
200
0
100
0
Min ∆p = 150 kPa
If the pump is equiped with pressure control, the valves must be calculated for the
lowest available ∆p. In this case 150 kPa, 1,5 bar, minus resistance in the heat
exchanger. All valves for which the available ∆p will exceed the design ∆p with
more than 50% require a ∆p control.
Fig, 7:12
Example, control valve and differential pressure control:
∆t = 50 oC
m3/h Valve kvs - value l/s
1 P = 1.500 kW; Q = 1.500 × 0,86 / 50 = 25.800 l/h.
50 15 ∆p available = 1,5 bar. ∆p heat exchanger = 0,3 bar.
0 ∆p = 1,5 - 0,3 = 1,2 bar.
30 1 3 2 4 4 25 10
7
20 16 5 2 ∆p available for ∆p valve = 1,2/2 = 0,6 bar;
10 3 Values for ∆p - valve from diagram: kvs = 40 m3/h;
10
7 6,3 2
3 ∆pv = 0,41 bar
5 4,0
1,0
3 2,5 0,7 4 ∆p available for control valve = 1,2-0,41 = 0,79
2 1,6 0,5 bar
1,0 1,0 0,3 kvs = 40 m3/h; ∆pv = 0,41 bar;
0,7 ,63 0,2 Pre-set value for the ∆p control = 0,41 bar;
0,5 ,4
0,3 0,1
,07
0,2
,05
0,1 ,03
10 20 30 40 60 100 150 kPa
∆pvalve

1 2 3 4 5 7 10 15 20 mWG

Fig, 7:13 0,1 ,2 ,3 ,4 ,5 ,7 1,0 1,5 2 Bar

8 STEPS - CONTROL OF HEATING SYSTEMS 147

 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Setting value.
A differential pressure control keeps the differential pressure constant
across a circuit. The setting value for the differential pressure control is
equal to the resistance in that particular circuit.

Secondary systems.
In the secondary systems differential pressure controls are used to keep
the differential pressure constant across a control valve or a part of the
system, for example a riser or a two-pipe radiator circuit containing
several thermostatic valves.

Available differential pressure.

In secondary systems, the resistance in the design circuit, of which the
differential pressure control is a part, is calculated. It is important when
calculating to check the requirements for the differential pressure control
in question. Some of these differential pressure controls require a
minimum differential pressure to function properly.
The resistance across the differential pressure control in the design
circuit is obtained from the selection flow chart. Enter the flow in
question into the selection flow chart then select valve size and read the
resistance.
For the other circuits the available differential pressure is obtained from
the pipe calculation.

Valve size.
Differential pressure control across a control valve.
In the designed circuit first of all check if the differential pressure control
requires a minimum differential pressure. Is this the case, select a size of
control which requires at least this pressure. Even if the resistance across
the smallest valve is not large enough make sure that at least the
minimum differential pressure is available. Select accordingly the size of
the control valve.
The available pressure in the other circuits is divided by two. The control
valve is selected first and the remaining differential pressure is used for
selection of the differential pressure controller.

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

∆pvalve
< 15 kPa
∆ppump
1 2 3 4 5 6 7 8 9

Example
∆psystem ∆p 100%
∆p Pa ∆p at 0% Q = 3m2/h
With max ∆p ∆ppump = constant
60
50
40 With proportional ∆p ∆pavailable = from the calculation of the design
30
circuit, including valve no 9.
20
∆pvalves no
10 Here: from the above diagram ∆p valve 9.
0
Excessive ∆p ∆pexc. = ∆pavailable - ∆pvalve
Design ∆p ∆ppump = ∆psytem + ∆p control and differential
Available ∆p with or without Without pump control or with constant ∆p pressure valves no 9.
pump control at different flow With proportional or parallel pump contol ∆psystem = 60 kpa.
Fig. 7:14 Sizing of the control and differential pressure
control valves no 9.
Sizing of the control valves and differential pressure control valves in the above See flow chart: 9. 3m3/h ∆p control valve <15 kPa.
heating circuit.
∆p valve no 9 kvs 10, ∆p = 9 kPa.
The ∆p control valve will be the same size
m3/h Valve kvs-value m3/h l/s and ∆p ∆pvalves = 18 kPa.
200 50 ∆ppump = 60 + 9 + 9 = 78 kPa.
145 Selecting valve size from flow chart:
100 30
100 Divide the total available ∆p by 2.
63 20
Find in flow chart the cutting point between flow,
50 40
10
3 m3/h, and the ∆p available for the valve.
30 25 Choose the first valve size which is big enough.
7
20 16 5 Find ∆p across the chosen valve, that is the set pressure
10 for the differential pressure control.
10 3
42 The two valves will have the same size.
7 7 6,3 2
5 Valve ∆pavailable kvs ∆pvalve ∆pvalves
9 8 6 3 1 4,0
5 1,0
3 2,5 0,7
Total 1 valve
2 1,6 0,5 1 53+18=71 35 6,3 23 46
2 44+18=6 31 6,3 23 46
1,0 1,0 0,3 3 39+18=57 28 6,3 23 46
0,7 ,63 0,2 4 34+18=52 26 6,3 23 46
0,5 5 29+18=47 23 6,3 23 46
,4 6 24+18=42 21 10 9 18
0,3 0,1
,07 7 19+18=37 18 10 9 18
0,2 8 12+18=30 15 10 9 18
,05
,03 Calculation of valve no 9.
0,1
1 2 3 4 5 7 10 20 30 40 60 100 150 200 kPa 3
kv = ; kv = 7,8; => valve with kv 10,0;
∆pvalves

0,1 0,2 ,3 ,4 ,5 ,7 1 2 3 4 5 7 10 15 20 mWG √ 0,15

0,01 ,02 ,04 ,06 0,1 ,2 ,3 ,4 ,5 ,7 1,0 1,5 2 Bar ∆p =
( 103 ) ; 2 ∆p = 0,09 bar; => 9 kPa.
v
Choosing valves from a flow chart will not give the mathematical accuracy
as a calculation, but it is good enough when considering the inaccuracy of the
underlying calculations.
Fig. 7:15
8 STEPS - CONTROL OF HEATING SYSTEMS 149
 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Differential pressure control of risers.

With regard to the design circuit, it is first of all a question of checking
if the differential pressure control requires a lowest differential pressure.
If so, choose a size of control that requires at least this pressure, or make
a reservation for the lowest required pressure for the control, even if the
resistance across it is not very large.
Concerning the other circuits, the flow and the available differential
pressure are entered in the selection flow chart and a suitable valve size
is chosen.

∆p 5 kPa 1

∆p 9 6
∆p 9
∆p 80 kPa 140 133 125 ∆p 9 kPa 7

∆p 72 kPa

Available ∆p for the risers with ∆p-control valves.

Fig. 7:16

l/h Valve kvs - value Set values l/s

500
140 ,1
300 N
125 ,07
200 7 6 ,05
1 7
100 5 ,03
4
70 0,60 0,45 ,02
50 3
0,36 0,27 2 ,01
30
0,20 0,12 ,007
20 ,005
1
kv
1 2 3 4 5 6 7 N 10 0,08 ,003
RTD-N 15 0,04 0,08 0,12 0,20 0,27 0,36 0,45 0,60 7 ,002
RTD-N 20 0,10 0,15 0,17 0,25 0,32 0,41 0,62 0,83
0,04
5
RTD-N 25 0,10 0,15 0,17 0,25 0,32 0,41 0,62 0,83 ,001
3
Radiator l/h ∆p kPa Pre-set 1 2 3 4 5 7 10 20 30 kPa
∆pvalve

1 140 5 N 0,1 0,2 ,3 ,4 ,5 ,7 1 2 3 mWG

7 140 9 7 0,01 ,02 ,04 ,06 0,1 ,2 ,3 Bar
125 140 9 7 Calculation of the pre-set values for the valves in the above system with ∆p control
valves in the riser.
140 140 9 7
Fig. 7:17

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Setting value.
A differential pressure control keeps the differential pressure constant
across a circuit. The setting value for the differential pressure control is
equal to the resistance in that particular circuit.

∆p 5 kPa 1

∆p 9 6
∆p 9
140 133 126 ∆p 9 kPa 7

20 19 18 2 1
∆p kPa 89 85 81 22 18

Q in each riser = 980 l/h

Available ∆p for the ∆p-control valves at each riser.
Fig. 7:18

ASV-P, ASV-PV Min. available ∆p Sizing of ∆p-valve in riser.

Q in each riser = 980 l/h
m3/h Valve kvs-value l/s ∆p riser = 9 kPa.
10 3 Max. ∆pvalve Valve no 1 , se diagram.
10
7 2 kvs = 4,0, ∆pvp = 6 kPa
5 6,3 ∆p-valve with fixed ∆p = 10 kPa and
4,0 1,0 minimum available ∆p = 8 kPa gives 18 kPa.
3 0,7
2 2,5
0,5 Valves 2, 18, 19 and 20.
1 2 18-20 1,6
1,0 0,3 ∆p-valve Q l/h ∆pavail.-∆priser = ∆pvp avail kvs ∆pvp
0,7 0,2
0,5 2 980 22 10 12 4,0 6
0,1
0,3 18 980 81 10 71 1,6 37
7 10 20 30 40 60 100 kPa
19 980 85 10 75 1,6 37
∆pvalve

,7 1 2 3 4 5 7 10 mWG
20 980 89 10 79 1,6 37
,06 ,1 ,2 ,3 ,4 ,5 ,1 1

Sizing of the ∆p-valves in the riser

Fig. 7:19

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Flow limitation.
Flow limitation is required in both primary and secondary systems.

Primary systems.
In a primary system, it is the flow to a whole sub-station or to the applied
heat exchangers that should be limited.
The heat supply is controlled by a control valve and if the differential
pressure across this valve is kept constant with a differential pressure
control the sub-station contains the required components to limit the
flow.
Calculate the differential pressure that is necessary across the fully open
valve to obtain required flow. Set the differential pressure control so that
it will provide the differential pressure and the maximun flow is limited.
Combined flow limiters consisting of a differential pressure control and
k vs 4,0 a setting valve are available. The differential pressure control keeps a
constant differential pressure across the integrated pre-set valve. The size
∆pvalve kPa of the flow is determined by changing the resistance across the setting
valve. When large sizes are required a flow limitation is obtained as a
differential pressure control can keep a constant differential pressure
across a integrated pre-set valve. The valve size is determined in a
Example, limiting the flow in a primary circuit.
selection flow chart on basis of the available differential pressure and the
Control valve kvs 4,0
flow.
Ex. no Q m3/h ∆pvalve. ∆pvp-set m3/h kvs-value l/s
10 3
1. 3 55 55 7 2
2. 4 100 100 5
1 2 1,0
3. 1 6,3 6,3 3
0,7
2 4 0,5
The ∆p necessary for a specific flow through a fully
3
open control valve is equal to the setting ∆p for the 1,0 0,3
differential pressure control. 0,7 0,2
Calculation 0,5
1 ∆pv = ( 43 ) ; ∆pv = 0,56 bar => 56 kPa;
2
0,3
0,1
,07
0,2 ,05
∆pv = ( 44 ) ; ∆pv = 1 bar => 100 kPa;
2
2
0,1 ,03
∆pv = ( 1 ) ; ∆pv = 0,0625 bar => 6,3 kPa;
2 1 2 3 4 5 7 10 20 30 40 60 100 kPa
3
4
∆p 0,1 0,2 ,3 ,4 ,5 ,7 1 2 3 4 5 7 10 mWG
Fig. 7:20 0,01 ,02 ,04 ,06 0,1 ,2 ,3 ,4 ,5 ,7 1,0 Bar
Limiting the flow in a sub - station equiped with ∆p control valve
Fig. 7:21

152 8 STEPS - CONTROL OF HEATING SYSTEMS

 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Secondary systems.
In secondary systems the limitation of the flow could come into
question to a shunt coupling, a riser or a one-pipe circuit.
If there already is a control valve and a differential pressure control in a
shunt coupling, use these for the flow limitation too! Calculate the resis-
tance across a fully open control valve at the maximum required flow and
set the differential pressure control on this differential pressure!
In other cases there are flow limiters keeping the differential pressure
constant across a built-in adjustment valve. They are often sized
according to the available differential pressure and the required flow.
Setting value is read in the selection flow chart.

Example, limiting the flow in a primary circuit.

Control valve kvs 1,6
∆p-valve kvs 1,6
m3/h kvs-value l/s Ex. no Q m3/h ∆pvalve. ∆pvp-set ∆p-contr
10 3
7 2 1. 0,4 5,8 5,8 ASV-PV
5
1,0 2. 0,8 25 25 ASV-PV
3
0,7 3. 1,5 90 90 AVP
2 3 0,5
The ∆p necessary for a specific flow through a fully
1,0 2 1,6 0,3 open control valve is equal to the setting ∆p for the
0,7 0,2 differential pressure control.
0,5 1 ASV-PV: setting range 5-25 kPa.
0,3 0,1
,07 AVP: setting range 5-50, 20-100 and 80-160 kPa.
0,2 ,05 Calculation
0,1
,03 1 ∆pv = ( 0,41,6 ) ; ∆pv = 0,0625 bar => 6,3 kPa;
2

1 2 3 4 5 7 10 20 30 40 60 100 kPa
∆pv = ( 1,6 ) ; ∆pv = 0,25 bar => 25 kPa;
0,8 2
∆p 0,1 0,2 ,3 ,4 ,5 ,7 1 2 3 4 5 7 10 mWG 2

∆pv = ( 1,6 ) ; ∆pv = 0,88 bar => 88 kPa;

0,01 ,02 ,04 ,06 0,1 ,2 ,3 ,4 ,5 ,7 1,0 Bar 1,5 2
3

Fig. 7:23
Limiting the flow for a control valve in a secondary circuit with ∆p control.
Fig. 7:22

8 STEPS - CONTROL OF HEATING SYSTEMS 153

 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Flow limitation in a one-pipe circuit

∆p available > ∆p1-pipe circuit + ∆pv
∆pv = 25 kPa

Example, ASV-Q
ASV-Q Capacity l/h Setting value
15 100-800 1-8
20 200-1400 2-14
25 400-1600 4-16
32 500-2500 5-3
Q = 1100 l/h
Choose ASV-Q 20
(always choose the smallest possible valve)
Setting value = 11

∆p one-pipe circuit
∆pv

∆p available

Flow limitation in a one-pipe circuit

Fig. 7:24

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Control equipment.
Different control equipment is required for different purposes. The
control of the flow temperature to radiators requires one type of control,
hot water heating requires another, and ventilation devices require a third
type. For the last two cases there is also a choice between electronic and
self-acting control.

Radiator systems.
The flow temperature in radiator systems is controlled according to the
outdoor temperature by a weather compensator.
The electronic central control can be equipped with timers with twenty-
four hours or weekly functions. This is however only the case if the heat
supply is set back during a period of several days and nights and if the
system is not connected to a computer.
A pump stop is an optional function which shuts off the circulation
pump when the outdoor temperature is so high that the building requires
no heating.
The limitation of the return temperature is usually not required in the
two-pipe systems with thermostatic valves.
A computerized supervision and control system is a labour-saving and
efficient way of controlling large systems with many sub-stations.

Weather compensator

Outdoor temperature sensor

Surface sensor

Reversible gear motor

Necessary control equipment for sub-station

Fig.7:25

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Hot water heating.

Water is heated in a heat exchanger or in an accumulator.
The heat supply for the two types of hot water heating can be controlled
by a weather compensator with an extra function for this purpose or self-
acting controls for the accumulating hot water tanks.
For heat exchangers up to 30 apartments there are self-acting controls
with flow compensation available.

Flow compensated thermostatic valve for control of domestic hot water tempera-
ture.
Fig. 7:26

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Pipes and heat exchangers.

Pipes for heating.
When designing pipe systems an economic water rate has to be maintained.
Too low a rate will give large-size pipes, deposits in the pipes, larger heat
losses and temperature drops, but of course also a lower flow resistance
and thereby lower operating costs for the pump.
An optimization reflecting the costs for pre-insulated pipes gives water
rates of approximately 0,6 m/s for the internal diameter of 27 mm to 3,6
m/s for the internal diameter of 1.220 mm.
The corresponding values for insulated standard pipes in the heating
system of a building will give about 0,3 m/s for pipes with an internal
diameter of 10 mm and 1,5 m/s for an internal diameter of 150 mm.

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Pipes for domestic water.

There are three types of pipe material to choose from for the domestic
water - galvanized steel, copper and plastic. All of them can as a rule be
used for cold water, but copper and plastic are superior. For hot water
only copper and special plastic pipes can be used.
Copper pipes are sensitive to high water rates and they are environmen-
tally hazardous, (copper is transported together with the sewage down to
the purification plant and will there affect the purification process nega-
tively).
Maximum rates in an easily exchangable pipe:
• cold water 2 m/s
• hot water 1,5 m/s
For plastic pipes there are no limits to the water rate, but pipes intended
for domestic hot water must endure the temperature in question for
many years – 50 years according to international standards, NKB
Product rules, 3, July 1986 and DIN 16892.

Heat exchangers.
Modern heat exchangers, plate and coil units, contain small quantities of
water and the flow channels are narrow. By making them short and by
Domestic hot water, Q l/s Effect, P kW laying a large number of them parallel, the flow resistance is kept at a low
2,5
400
level in spite of a relatively high water rate.
2,0 350
300 The high water rate is necessary to prevent deposits from settling on the
1,5
250
200
heat transferring surfaces.
1,0
150
0,5 100 The resistance across the coil unit is in the range of 20-30 kPa and for
0
50
0
the plate heat exchanger the resistance is up to 50 kPa. The choice of size
1 10 50 100 150 200 250 is made according to the instructions from the manufacturer. There are
Number of apartments
domestic water selection flow charts, based on empirical values, giving
Maximum required flow according to the Swedish the total consumption for various number of apartments.
Board for District Heating
Fig. 7:27

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Heat meters.
Heat meters register the delivery to each building/apartment, but they
also indicate if anything goes wrong in the system. As there are large
variations in the flow, a flow meter must also be able to measure low flows Accumulator
with great accuracy. Heat meter

The primary network.

Meters on the primary side register the heat consumption, i.e. flow and
temperature drops. The meters should be based on ultrasound, and the Heat meter
integration unit should be able to communicate with a central computer.
The theoretical maximum flow determines the size of the flow
meters.The ultrasonic meter has an advantage of being able to measure Heat meters register consumption and heat losses
from pipe network.
the lowest flows very well, independent of size. Fig. 7:28
Each heat exchanger for heating and for domestic hot water should be
equipped with a heat meter.

The secondary network.

On the secondary side, it is sufficient to measure the flow for each
apartment. Based on this, make a percentage calculated distribution
between the apartments of the total heat supply to the building. Then use
a flow meter, mechanical or ultrasonic to register the flow to each
apartment.
The variations in flow can be considerable, so it is important to carefully
register the low flows here.
Flow meters based upon ultrasound are therefore the most suitable
choice, especially when considering the large numbers and the fact that
the ultrasonic meters require practically no maintenance.
The choice of the flow meter sizes is made according to the theoretical
maximum flow to each apartment.
If the distribution of the heating costs is to be consistent, the hot domes-
tic water to each apartment ought to be registered too, which requires
that the riser for hot domestic water be placed centrally, in the stair-well,
Flow meters register the flow to each apartment
and that separate pipes are laid from there to each apartment. Fig. 7:29

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 CHAPTER 7 • HOW TO SELECT SIZE OF PRODUCTS AND COMPONENTS.

Pressure control of pumps.

The pressure control of pumps should be applied on the primary and the
secondary sides to reduce the consumption of electricity. The effect on
the available pressure will be marginal as the differential pressure control
is applied on control valves or parts of the systems.

The primary network.

The required pressure and flow on the primary side is always so high
that it requires a pump with a separate motor. The motor is a standard
induction motor and a frequency converter is therefore the most suitable
choice for control.
Frequency converters are available in the same sizes as the ones being
standard for the standard induction motors. There are therefore no
problems in selecting the size. Choose a frequency converter
corresponding to the size of the motor!

The secondary network.

There are pumps with a wet motor and a built-in pressure control
available for the secondary side. These pumps should be used as far as
possible and when their capacity isn’t sufficient to meet the requirements,
dry pumps and frequency converters should be chosen. The largest cut in
the operating costs for the pump is obtained when the differential pres-
sure is kept constant at the last riser/valve.

% ∆p, P
100

50 2
∆p n =∆Q x p 0

3
P n =∆Q 0 xP 0

0
Q 0 50 100%

The resistance varies by the square of the flow change and the effect of the pump
by the cubic
Fig. 7:30

160 8 STEPS - CONTROL OF HEATING SYSTEMS