Professional Documents
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Pumps and static heads are used to force circulation in Open Systems except as noted
Steam supply
Open steam condensate return (gravitational)
Closed condensate return
Cooling tower water (partially gravitational)
Fuel oil supply
Fuel oil return
Gasoline supply
Fuel gas supply
Domestic cold water supply
Domestic hot water supply
Storm sewer return (gravitational)
Sanitary sewer return (gravitational)
Sanitary vents (gravitational)
Closed systems apply mainly to liquids. Examples of closed network systems include
Chilled water
HVAC hot water
High temperature hot water
Glycols
Brines
Supply-Return Systems
Primary-Secondary Systems
Network arrangements can be combinations of direct return and reverse return loops.
Fluid types used in HVAC include water, brine, glycol, diesel oil, steam and fuel gas. Water
systems can be temperatures (40 F to 210 F) at standard pressure; temperatures (210 F to 250 F)
at medium pressure; and temperatures (up to 400 F) at high pressure. Properties include
kinematic viscosity, density and specific heat at different temperatures. In the case of steam, the
properties are saturation temperature, saturation pressure, specific volume and latent heat at
different pressures.
Pipe Materials
Properties for each nominal pipe size include inner and outer diameters, weight per unit length,
and pipe wall thickness. Other pipe properties include thermal conductivity, inside roughness
factors,
roughness correction factors for the age of the pipe.
Pipe Insulation
Pipe insulations include fibrous glass, urethane, elastomerics, phenolic foam, calcium silicate and
magnesia. Properties include density and thermal conductivity at different temperatures.
Fittings are piping components that create dynamic pressure losses in the network. Loss
calculations are based on the Hydraulic Institute Engineering Data Book, 1979. A list of fitting
types is shown in Fittings and Valves in this engineering basis. Fitting data include K values for
different pipe diameters, velocities, radius bends and contraction/expansion angles. An
alternative to the K value method, is the use of equivalent straight pipe lengths (L/D) values for
fittings and valves.
Design standards include maximum velocity, pressure loss per unit length and flow for different
types of fluids, pipe materials, pipe sizes and applications. Cross-reference tables are included to
check that the appropriate pipe material is used for a given application, fluid type and insulation
type
The plumbing drainage design criteria consist of tables for analyzing and sizing roof drains and
leaders, horizontal rain water pipes, building drains and sewers, horizontal fixture branches and
stacks, and horizontal and vertical vents. Fixture units values for fittings are also included in the
library. Sizing criteria and tables are provided by ASPE.
Piping System
Equipment in the piping system network must be analyzed and designed for:
Entering and Leaving Pressures,
Pressure loss,
Entering and Leaving Temperatures
Temperature Change.
Network Identification
Pipe Sections: A piping system is made up of linked pipe sections. The physical properties of the
pipe and the properties of the fluid flow inside the pipe section are unique to the section. By
definition a pipe section occurs under one or more of these conditions:
the pipe section contains fluid handling equipment; (a new section must begin
downstream of such equipment)
Supply Sections: Pipe sections from the discharge side of the primary pumping station node to
the section with the terminal equipment are defined as supply sections.
Return Sections : Pipe sections on the downstream side of the terminal equipment to the
suction side of the primary pump are defined as return sections.
Exclude Sections (or independent sections): These are defined as pipes that are not part of the
supply or return tree networks. Examples of such pipe sections are bypass piping at terminal
equipment, parallel piping at pump stations & primary equipment, and piping to compression
tanks.
Pipe Circuit is a series of pipe sections from the pump to the terminal equipment (heat
exchanging equipment, plumbing fixture, etc.) for open systems and back to the pump for closed
systems.
Exception: In the case of cooling tower and condenser water systems, the piping from the
cooling tower to the condenser is Supply, and from the condenser and pumps to the cooling
tower is Return.
Terminal equipment (unit heaters, fan coil units, etc.) is not usually connected in series within a
section of the piping network system. Therefore, the number of pipe circuits in a piping system is
equal to the number of terminal equipment units.
Piping Network
A piping network consists of several circuits. A supply network begins with a single pipe section
that is common to all the circuits. This section is referred to as the first section in the supply side
of the network. Similarly, a return network ends with a last section.
The first section of the network must have enough pressure to drive the fluid through all the
circuits in the network. This starting pressure is the highest circuit pressure loss. In the case of
steam and fuel gas, the starting design pressure is determined by the application’s requirements.
For steam, initial pressure can also be calculated from the initial temperature that you specify.
Plumbing drainage and steam condensate return systems are based on gravitational flow. Sizing
is based on tables provided by ASPE.
The source of network pressure in the first supply section for liquid systems is typically a pump or
group of pumps referred to as the primary pumping station. In addition to this primary source of
pressure, the pressure in any secondary circuit ca be boosted using a booster pump.
Use only one booster pump in series with the primary pump in any one circuit. A piping network
may consist of a primary system and one or more secondary systems arranged in a series with
the primary system
Fig. 1-3 shows a primary-secondary system. The primary pumping station consists of six pumps
arranged in a 3-parallel x 2-series system. All the pumps in the pumping station are identical in
type and size. This is recommended design. The flow in each pump is, therefore, one-third or
the total system flow and the pressure head for each pump is one-half of the required system
head.
The entire pumping station is treated as a single pressure source with a first supply (S) section
(101) leaving the system and a last return (R) section (201) entering the system. All the other
sections in the pumping station are identified as X sections that must be excluded from the
network analysis.
The piping network identification information from Fig. 1-3 is shown in tabular form in Fig. 1-4.
This information is rearranged and presented in Fig. 1-5 through Fig. 1-9 as circuits with the
sections in each circuit arranged in flow sequence.
Fig. 1-5 shows complete circuits starting from the primary pumping station, passing through a
terminal equipment and back to the pumping station. This is the typical circuit arrangement
when there are no booster pumps.
20 103 - S - BP-1 -
21 20 - S - - -
22 21 - S TE-1 - -
23 21 - S ─ - -
24 23 - S TE-2 - -
25 23 - S TE-3 - -
26 - 28 R - - -
27
30 -
10 28
- RS -- -
BP-2 --
31 30 - S - - -
32 31 - S TE-4 - -
33 31 - S TE-5 - -
34 - 36 R - - -
35 - 36 R - - -
36 - 205 R - - -
40 105 0 S TE-6 - -
41 - 204 R - - -
50 106 - S - - -
51 50 - S - - -
52 51 - S TE-7 - -
53 51 - S TE-8 - -
54 - 56 R - - -
55 - 56 R - - -
56 - 203 R - - -
71 - - X - - -
72 - - X - - -
81 - - X - - -
82 - - X - - -
83 - - X - - -
84 - - X - - -
85 - - X - - -
91 - - X - - -
101 Pump - S - - PE-1
102 101 - S - - -
103 102 - S - - -
104 103 - S - - -
105 104 - S - - -
106 105 - S - - -
201 Pump R - - -
203 201 R - - -
204 - 203 R - - -
205 - 204 R - - -
206 - 205 R - - -
-
Fig. 1-6 is the primary system and Fig. 1-7, Fig. 1-8 and Fig. 1-9 are the secondary systems. Note
that the circuit that passes through the terminal equipment having the label TE-6 does not have a
booster pump. That entire circuit becomes a part of the primary system.
Ckt # of
Sections in Each Circuit Arranged in Flow Sequence
No. Sect
1 20
4 101 102 103
BP-1
30
2 5 101 102 103 104
BP-2
40 201
3 10 101 102 103 104 105 41 204 203
TE-6 BP-2
50
4 7 101 102 103 104 105 106
BP-3
Ckt # of
Sections in Each Circuit Arranged in Flow Sequence
No. Sect
Ckt # of
Sections in Each Circuit Arranged in Flow Sequence
No. Sect
1 6 51 52 55 56 293 201
TE-7
2 6 51 53 54 56 203 201
Ckt # of
Sections in Each Circuit Arranged in Flow Sequence
No. Sect
20 22
1 12 101 102 103
BP-1
21
TE-1
29 206 205 204 203 201
20 24
2 14 101 102 103
BP-1
21 23
TE-2
27 28 206 205 204 203 201
20 25
3 14 101 102 103
BP-1
21 23
TE-3
26 28 206 205 204 203 201
30 32
4 13 101 102 103 104
BP-2
31
TE-4
35 36 205 204 203 201
30 33
5 13 101 102 103 104
BP-2
31
TE-5
34 36 205 204 203 201
40
6 10 101 102 103 104 105
TE-6
41 204 203 201
50 52
7 13 101 102 103 104 105 106
BP-3
51
TE-7
55 56 203 201
50 53
8 13 101 102 103 104 105 106
BP-3
51
TE-8
54 56 203 201
Fig. 1-10 shows a closed system network. The system shown is a reverse return system with
both supply and return sections. Closed systems are not affected by atmospheric pressure. The
pump head of open systems include atmospheric pressure. Fig. 1-11 illustrates an open supply
system.
Network Analysis
The piping system analysis uses a general tree structure. A pipe network can be either an open
or closed network. To simplify analysis, a closed network can be divided into two open networks,
one supply and one return, with the break between them at the terminal equipment.
An open network can be analyzed as a tree with a single trunk fanning out into branches, sub-
branches, then leaves. Forward network analyses begin with the main pump (tree trunk) and
work down each pipe section (branch, sub-branch) to a terminal equipment (leaf). Reverse
network analysis works from a terminal equipment to the pump.
The tree structure is handled as a number of linear linked lists, one for each junction in the pipe
network. A pipe section is analyzed only once and and the sections are arranged in flow
sequence into complete circuits.
The pipe sections are linked into circuits. A supply section can have only one upstream section
and any number of downstream sections. A return section can have only one downstream
section and any number of upstream sections.
The network analysis to determine the fluid flow in each pipe section starts with each terminal
equipment, a circuit end, and moves backwards, assigning the fluid quantity of the terminal
equipment to all the sections in the circuit.
Thermal analysis begins with the fluid temperature leaving the primary equipment section, and
moves forward through each section in the circuit. The heat gains or losses and the temperature
at the end of each section are calculated.
The temperature at the end of the last section in the circuit is the actual fluid temperature at the
terminal equipment. The pressure analysis also moves forward through the network, starting at
the pump section.
Fig. 1-12 through Fig. 1-16 are examples of basic liquid system. The systems described in the
next few pages use water, although brine and glycol may be substituted in the piping network
system.
A two-pipe direct return system illustrated in Fig. 1-12 is difficult to balance because the terminal
equipment with the shortest supply line also has the shortest return line. The circuit analysis
report will indicate the balancing requirements of each circuit.
A two-pipe reverse return system illustrated in Fig. 1-13 provides uniform pressure drop through
all the heating units. The length of straight piping through all the circuits is approximately the
same. The unbalanced pressure heads are primarily due to equipment and fitting losses in the
circuits.
By definition, a secondary system is created when a booster pump is located in one of the
sections. Fig. 1-3 shows a primary system with three secondary systems downstream of these
booster pumps.
Fig. 1-14 shows a reverse-return primary loop and direct-retur secondary loops. Since there are
no booster pumps, the entire network is treated as one primary system.
Primary loops may be direct-return or reverse-return. They may be combined with one or more
secondary loops that may all be direct-return, reverse-return, or a combination of the two.
From Fig. 1-13 and Fig. 1-14, you can see that secondary systems are also secondary loops, but
secondary loops are not always secondary systems.
Three-Pipe Systems
The three-pipe system illustrated in Fig. 1-15 uses two piping systems to supply the terminal
equipment, one for cold water and the other for hot water, along with a common return.
The three-pipe system may be terminal mix or return mix. In both types, hot and cold water is
provided at the terminal equipment. In the terminal mix system, hot and cold water are mixed at
the terminal equipment to obtain the required equipment temperature.
In the return mix system, each terminal equipment in the network uses either hot water or cold
water and discharges into a common return system where mixing takes place.
Four-Pipe Systems
The four-pipe system, illustrated in Fig. 1-16, derives its name from the four pipes to and from
each terminal equipment: cold water supply, cold water return, hot water supply and hot water
return. The four-pipe system satisfies the variations in the heating and cooling loads by providing
independent sources of heating and cooling to the room or zone. During the period between
seasons, any unit can be operated at maximum heating or maximum cooling.
Systems
Systems types are based on the application, fluid type and piping arrangement (open or closed)
Density and kinematic viscosity are used in frictional loss calculations. The specific heat is used in
thermal analysis. Default fluids are 50% ethylene glycol, 25% calcium chloride, diesel fuel oil #2,
and gasoline with a specific gravity of 0.72. In Fig. 1-19 and Fig. 1-20, the defaults shown express
kinematic viscosity in 10-6. Glycol may be a different concentration of ethylene glycol or glycerol.
Brine may be a different concentration of sodium chloride or calcium chloride. Diesel fuel oil and
gasoline may represent different blends of these liquids.
Temperature oF
Liquid Properties
-30 0 30 60 100 150 212
Density (lb/cu ft)
62.42 62.37 62.00 61.20 59.81
Kinematic viscosity (sq
WATER 20.0 12.17 7.39 4.76 3.2
ft/sec)
Specific heat (Btu/lb oF) 1.0 1.0 1.0 1.0 1.005
Density (lb/cu ft)
67.98 67.55 67.11 66.55 65.74 64.68 63.12
Kinematic viscosity (sq
GLYCOL 595.0 190.0 85.4 48.6 22.6 12.5 6.4
ft/sec)
Specific heat (Btu/lb oF) 0.70 0.73 0.76 0.78 0.81 0.85 0.88
Density (lb/cu ft)
78.59 78.21 77.71 77.21 76.09
Kinematic viscosity (sq
BRINE 171.7 77.5 34.7 21.8 8.9
ft/sec)
Specific heat (Btu/lb oF) 0.66 0.67 0.68 0.69 0.71
Density (lb/cu ft)
59.2 57.4 56.1 54.9 53.0 51.1
Kinematic viscosity (sq
DIESEL 376.7 161.5 80.7 48.3 29.1 7.5
ft/sec)
Specific heat (Btu/lb oF) 0.47 0.48 0.49 0.50 0.51 0.52
Density (lb/cu ft)
46.1 45.5 44.9 44.7 44.3 42.4
GASOLI Kinematic viscosity (sq
11.0 9.8 8.8 7.0 5.5 3.0
NE ft/sec)
Specific heat (Btu/lb oF) 0.47 0.48 0.49 0.50 0.51 0.52
Fig. 1-19: Properties of Liquids (Water, Glycol, Brine, Diesel and Gasoline)
The temperature range for water in Fig. 1-19 is 32F to 212F. Fig. 1-20 shows the properties of
water for the HTHW system type (high temperature hot water). The temperature range for
HTHW is 212F to 450F. It includes the temperature range defined in the 1987 ASHRAE
Handbook for medium temperature hot water (212 to 350). An additional fluid property,
saturation pressure, is included in this table and is included in the output reports for your
information. The saturation pressures are not used in the calculations.
Properties of Steam
Fig. 1-21 and Fig. 1-22, compiled from information published in Flow of Fluids, Crane, pp. A-2, A-
9, A-12 to A-14, show the properties of steam. Portions of this information can also be found in
manufacturers' steam tables. The information in this table is used in the thermal analysis to
determine the quality of steam
Enthalpy
Specific Enthalpy Kinematic Isentropic
Pressure o Saturate Specific
Temp. F Volume Evaporatn Viscosity Exponent
PSIG d Liquid Heat Cp
cuft/lb Btu/lb sq ft/sec K = Cp/Cy
Btu/lb
Enthalpy
Specific Enthalpy Kinematic Isentropic
Pressure o Saturate Specific
Temp. F Volume Evaporatn Viscosity Exponent
PSIG d Liquid Heat Cp
cuft/lb Btu/lb sq ft/sec K = Cp/Cy
Btu/lb
Pipe Materials
Materi Material
Description Description
al Code Code
S40 Schedule 40 steel CI 250 250 psi cast iron
S80 Schedule 80 steel CK Type K copper
ST Standard weight steel CL Type L copper
XS Extra strength steel CM Type M copper
CI 125 125 psi cast iron PVC PVC schedule 40 plastic
CI 175 175 psi cast iron CPVC CPVC schedule 40 plastic
The default information in the pipe materials library was compiled from the Hydraulic Institute
Engineering Data Book and the Hydraulic Handbook, Colt Industries. It can vary slightly with
manufacturer. Density (lb/cu ft) is used to calculate the weight of a pipe section. Conductivity
(btu/hr.oF.sp ft. in) is used in the thermal analysis. Inside roughness factors (ft) for open and
closed piping systems are used in the Colebrook equation to calculate the frictional loss in the
pipe .
Pipe Nominal
Roughness Factor Conduc
Materi Description Diameter Density
t-ivity
al Minim Maxim Closed Open
S40 Steel: Schedule 40 .250" 24" .00015 .0018 489.02 2.5
S80 Steel: Schedule 80 .250" 24" .00015 .0018 489.02 2.5
Steel: Standard
ST .250" 36" .00015 .0018 489.02 2.5
Weight
XS Steel: Extra Strength .250" 36" .00015 .0018 489.02 2.5
Cl 125 Cast Iron: 125 psi 3" 48" .00085 .0018 483.84 0.767
Cl 175 Cast Iron: 175 psi 3" 48" .00085 .0018 483.84 0.767
Cl 250 Cast Iron: 250 psi 6" 36" .00085 .0018 483.84 0.767
.00000 .00000
CK Copper: Type K .250" 12" 558.14 16.33
5 5
.00000 .00000
CL Copper: Type L .250" 12" 558.14 16.33
5 5
.00000 .00000
CM Copper: Type M .375" 12" 558.14 16.33
5 5
.00000 .00000
PVC Plastic: PVC .500" 12" 94.7 0.1
5 5
.00000 .00000
CPVC Plastic: CPVC .500" 6" 105.7 0.079
5 5
The minimum and maximum nominal diameter limits shown in Fig. 1-24 indicate the range of
sizes in Fig. 1-24, Fig. 1-26, Fig. 1-27, and Fig. 1-28. These figures contain inside and outside
diameters for each pipe material and each nominal size. A blank in these tables indicates that
the nominal size for that particular pipe material is not available.
Roughness Factors
Roughness factors shown in Fig. 1-24 for closed pipe systems were obtained from ASHRAE
Handbook: 1985 Fundamentals, Table 2, p. 2-10. Piping for open systems such as cooling tower
water systems is subject to corrosion and scaling over a period of time. Open system roughness
factors are included in the library, even though they are not a property of the pipe material but a
function of the usage and age of the pipes. The value shown in Fig. 1-24 for Schedule 40 steel is
based on Handbook of Air-Conditioning System Design, Chart 4, p. 3-23. The Colebrook-White
equation shown as equation 20 in Pipe Sizing was applied using trial values for the friction factor
f until results approximated those of that chart.
Values for other steel pipes and for cast iron pipes are assumed to be the same as those for the
Schedule 40 steel pipes with the same age and usage. The effect of corrosion on copper pipes is
assumed to be negligible. Plastic pipes are not affected by corrosion. The values shown in Fig. 1-
24 are identical for both closed and open systems.
Physical Dimensions
Nominal 125 PSI Cast Iron 175 PSI Cast Ironl 250 PSI Cast lron
Pipe Size Diameter (in.) Diameter (in.) Diameter (in.)
In. Outside Inside Outside Inside Outside Inside
2
2 1/2
3 3.96 3.06 3.96 3.00
4 5.00 4.04 5.00 3.96
5
6 7.10 6.08 7.10 6.00 7.22 6.00
8 9.30 8.18 9.30 8.10 9.42 8.00
10 11.40 10.16 11.40 10.04 11.60 10.00
12 13.50 12.14 13.50 12.00 13.78 12.00
14 15.65 14.17 15.65 14.01 15.98 14.00
16 17.80 16.20 17.80 16.02 18.16 16.00
18 19.92 18.18 19.92 18.00 20.34 18.00
20 22.06 20.22 22.06 20.00 22.54 20.00
22
24 26.32 24.22 26.32 24.00 26.90 24.00
26
28
30 32.40 30.00 32.74 30.00 33.46 30.00
32
34
36 38.70 35.98 39.16 36.00 40.04 36.00
42 45.10 42.02 45.58 42.02
48 51.40 47.98 51.98 48.06
Pipe Age
Fig. 1-29 shows the correction factor that can be applied to the frictional loss in order to account
for the age of the pipe. This factor is a function of the pipe size (surface areas to flow area). Fig.
1-29, is based on Hydraulic Handbook, Colt Industries, Table 6, p. 64, has been modified for pipes
used in buildings. Pipe age factors and pipe material roughness factors are closely related. You
can use the correction factor to design closed systems with any pipe material. The roughness
factors for pipes shown in Fig. 1-24 are for new and clean pipes and does not account for the age
of the pipe.
Insulation Types
Fig. 1-30 shows the insulation types used for piping in buildings It includes the five insulation
classes with typical insulation types within each class. For information on applications for each
insulation type, turn to the ASPE Data Book, Vol. 1, Fundamentals of Plumbing Design, 1983-
1984, p. 12-1. Insulation density is used to determine the weight of the insulation for the pipe
section. Conductivity is used in the thermal analysis.
Fig. 1-31 shows an alternative way to enter the insulation thickness for each pipe section. It uses
the recommended thickness for insulation code MG and pipe material code S40 as an example
Cross-Checking Tables
Fig. 1-32 shows the various types of pipe materials used for different types of piping systems.
Chilled
X X
Water
Condenser
X X
Water
Hot Water
X X X
(HVAC)
Domestic
X X X X
Cold Water
Domestic
X X X X
Hot Water
Glycol X
Brine X
Diesel X X X
Gasoline
Storm
X X X X
Drainage
Sanitary
X X X X
Drainage
Sanitary
Vents
Fuel Gas X
High Temp.
X X X
Hot Water
Steam X X X
Condensat
X X X
e
EL FG UF PF CS MG
SYSTEMS
INSULATION Elasto- Fibrous Uretha
ne
85%
Phenoli Calcium Magnes
meric Glass Foam c Foam Silicate ia
CW Chilled Water X X X X
C Condensed Water X
HW Hot Water HVAC X
DCW Domestic Cold Water X X X X
DHW Domestic Hot Water X X X
GLYCOL Glycol X X X
BRINE Brine X X X
DIESEL Diesel
GASOL Gasoline
STORM Storm Drainage
DRAIN Sanitary Drainage
VENT Sanitary Vents
FUELGAS Fuel Gas
HTHW High Temp. Hot X X X
Water
STEAM Steam X X X
COND Condensate X X X
Fixture units are used to estimate the flow quantities in domestic water supply and sanitary
drainage systems. Fixture units are quantitative values associated with the fixture to account for
the diversity of usage (not all fixtures are in use at the same time)
The total fixture unit data is used to calculate the flow rate in the main section. If a diversity
factor is also entered for the main section, then first calculate the flow based on the sum of all
total fixture units in the system, and multiply this flow by the diversity factor.
The remaining system analysis and design procedures are described in earlier sections of this
engineering basis and are summarized below.
A flow rate is assigned to all sections in the network based on the required flow rate at
the fixtures. See Network Analysis.
Pipe sizing options can be based on pressure drop per unit length, velocity or maximum
flow. See Sizing Criteria.
The Colebrook-White and Darcy-Weisbach equations are used to calculate the pressure
losses through pipe sections. See Pipe Sizing.
Fitting and valve loss calculations can be based on velocity pressure factors, K, or
equivalent lengths, L/D. See Fittings and Valves.
Heat gains and losses and temperature changes in the system are based on the thermal
data that you can specify in the input forms. See Thermal Analysis.
Static and dynamic heads are calculated for all nodes in the pipe network. See Circuit
Pressure Analysis.
The system can be designed to provide the minimum pressure required at fixtures and
maintain the maximum pressure limit at the water main. See Circuit Balancing.
The primary pump station is analyzed if a primary pump is used to develop the pressure
in the main pipe section. See Pump Performance Based on System Requirements.
Booster pumps can be located in any supply pipe circuit to increase the pressure in the
circuit. See Network Analysis.
Pressurization tanks can be located on the discharge side of the pump, on the suction
side of the pump, or at the high point of the pipe system. See Pressurization Tanks.
Sizing Criteria
The values, shown in Fig. 1-34, were obtained by reading points along lines drawn between two
points in ASHRAE Handbook: 1985 Fundamentals, Figure 1, p. 34.3. The criteria is based on the
following points in that figure.
Criteria Point 1 Point 2
Low 3 ft/100 ft for 1/2-in. pipe 10 ft/sec for 24-in. pipe
Design 5 ft/100 ft for 1/2-in. pipe 12 ft/sec for 24-in. pipe
High 7 ft/100 ft for 1/2-in. pipe 15 ft/sec for 24-in. pipe
Maximum 8 ft/100 ft for 1/2-in. pipe 18 ft/sec for 24-in. pipe
Pipe Criteria Low Criteria: Design Criteria: High Criteria: Maxim
Size P.D. / Veloc. Flow P.D. / Veloc. Flow P.D. / Veloc. Flow P.D. / Veloc. Flow
100 ft (ft/sec) (gpm) 100 ft (ft/sec) (gpm) 100 ft (ft/sec) (gpm) 100 ft (ft/sec) (gpm)
3/8 3.3 1.5 0.70 5.5 1.85 0.95 7.5 2.25 1.25 8.5 2.5 1.25
1/2 3.0 1.6 1.5 5.0 2.2 2.0 7.0 2.7 2.5 8.0 2.8 2.75
3/4 2.6 1.9 3.0 4.5 2.5 4.1 6.5 3.0 5.0 7.3 3.3 5.5
1 2.5 2.2 6.0 4.1 2.75 7.5 6.0 3.5 9.0 6.8 3.8 10
1 1/4 2.25 2.5 12 3.8 3.25 15 5.6 3.9 17 6.4 4.5 20
1 1/2 2.2 2.7 17 3.5 3.5 22 5.2 4.2 27 6.3 5.0 30
2 2.0 3.0 32 3.2 3.9 40 4.9 5.0 50 6.0 5.5 55
2 1/2 1.8 3.4 52 3.0 4.5 65 4.6 5.5 80 5.5 5.9 90
3 1.7 3.8 90 2.8 5.0 120 4.3 5.8 130 5.3 6.5 160
4 1.6 4.1 170 2.6 5.5 210 3.9 6.5 260 5.0 7.5 300
5 1.5 5.0 300 2.4 6.0 390 3.7 7.5 480 4.8 8.5 550
6 1.5 5.5 500 2.2 6.5 600 3.4 8.1 750 4.5 9.5 850
8 1.3 6.0 950 2.1 7.5 1200 3.2 9.1 1500 4.2 10.5 1700
10 1.25 7.0 1650 1.80 8.5 2100 3.0 10.0 2500 4.0 12.0 3000
12 1.2 7.5 2500 1.70 9.0 3200 2.8 11.0 4000 3.8 13.2 4600
14 1.1 7.8 3200 1.65 9.5 4000 2.7 11.5 5000 3.7 13.5 6000
16 1.1 8.2 4500 1.60 10.0 5500 2.60 12.0 7000 3.5 14.8 8000
18 1.05 8.8 6000 1.55 10.5 7500 2.50 13.25 9000 3.4 15.5 11000
20 1.02 9.0 8000 1.60 11.5 9700 2.40 13.5 12000 3.3 16.5 14500
22 1.05 9.7 10000 1.55 11.8 12500 2.35 14.4 16000 3.2 17.4 19000
24 1.00 10.0 12000 1.50 12.0 15000 2.30 15.0 19000 3.1 18.0 22000
26 1.00 10.5 14000 1.45 12.3 17000 2.25 15.5 22000 3.1 18.7 26000
28 0.95 11.0 16500 1.45 12.6 20000 2.25 16.0 25000 3.05 19.4 31000
30 0.95 11.5 20000 1.40 13.0 23000 2.20 16.5 29000 3.05 20.0 36000
32 0.93 11.7 24000 1.36 13.2 26000 2.13 16.7 33000 3.03 20.6 41000
34 0.91 11.9 26000 1.33 13.4 30000 2.06 16.9 37000 3.01 21.3 46000
36 0.90 12.0 28000 1.30 13.5 33000 2.00 17.2 42000 3.0 22.0 52000
42 0.85 12.5 36000 1.25 14.5 44000 1.95 18.0 55000 2.95 22.0 65000
48 0.80 13.0 45000 1.20 15.0 52000 1.85 18.0 65000 2.80 22.0 75000
Fig. 1-34: Pipe Sizing Criteria
Dynamic pressure losses are a function of the geometry of the fitting or valve, and the flow
velocity. There are two methods for determining the dynamic pressure losses through valves
and fittings. In the first method, the velocity pressure is multiplied by a resistance factor K. The
K factor is a function of the fitting or valve type and its diameter.
2
V
PD (fitting / valve) = K
2g
Fig. 1-35 and Fig. 1-36 show the coefficient C and exponent E for the equation that determines
the resistance factor K at varying diameters. The equation is:
K = C (diameter )E
Default values for C and E are shown in Fig. 1-35 and Fig. 1-36.
Values for water were estimated by reading off points from graphically presented data in the
Hydraulic Institute Engineering Data Book, pp. 58 and 59. That data is reproduced with permis-
sion in Fig. 1-39 and Fig. 1-40 in this engineering basis.
Values for glycol, brine, diesel and gasoline were based on the water K factors using K x 1/specific
gravity + 10%. Apply a contingency factor of 10% to account for the range of available qualities
and types for these liquids.
Another method to estimate pressure losses in valves and fittings is to use equivalent length to
diameter (L/D) ratios for different fluid types. Fig. 1-37 and Fig. 1-38 show default L/D. All values
are approximations.
The pressure loss through the fitting or valve is the frictional loss through an equivalent length of
pipe calculated using the Colebrook and Darcy-Weisbach equations.
L d (diameter)
L (Equivalent Length) =
D 12
The K factor for 90o bends of uniform diameters is shown in Fig. 1-41 (reproduced with
permission from the Hydraulic Institute Engineering Data Book, 1979). The K factor for
enlargement and contractions is obtained from these equations:
Fig. 1-35: Typical Fitting K Factors: S40 Pipe and Water (pressure loss calculation)
Fig. 1-36: Typical Valve K Factors: S40 Pipe and Water (pressure loss calculation)
4 BALL 10 12 14 10 8 10 10 ball
5 BFLY 50 59 68 50 40 0 0 butterfly
check swing -
6 CHECK1 150 176 204 150 120 75 100 screwed
check swing -
7 CHECK2 150 176 204 150 120 75 100 flanged
10 GATE_EM 10 12 14 10 8 10 10 EM gate
11 GATE_AM 10 12 14 10 8 10 10 AM gate
12 GLOBE1 350 410 477 350 280 300 350 globe - screwed
13 GLOBE2 350 410 477 350 280 300 350 globe - flanged
17 PLUG 150 176 204 150 120 130 150 plug, cock
19 QUK_OPN 350 410 477 350 280 300 350 quick open
23 FOOT 50 59 68 50 40 0 0 foot
24 OTHER 0 0 0 0 0 0 0 other
Fig. 1-39 & Fig 1-40: Resistance Coefficients of Fittings & Valves
Liquids
Control valves are associated with sections with terminal equipment. The valve flow coefficient
Cv is defined as the flow in U.S. gallons per minute of water at 60F with a pressure drop of 1 psi.
Cv is a measure of the valve flow capacity and is determined by flow tests.
Q = Cv PD (62.4 / )
where Q = flow (GPM)
Cv = valve flow coefficient
PD = pressure drop through valve at full flow and standard conditions (psi)
= weight density of fluid (lb/cu ft)
The pressure drop for water and liquids at other temperatures is calculated using the equation:
l 1
0.25
PD1 = PD s
s s
where PD = pressure drop through valve (psi)
= density of liquid (lb/cu ft)
= kinematic viscosity (sq ft/sec)
l,s = subscripts representing given liquid and standard liquid (water at 60F)
The pressure drop in psi is converted to feet of liquid with the equation:
pd l 144
PD =
l
where PD = pressure drop through valve (liquids)
Steam
The equation for pressure drop for steam at full flow using the valve flow coefficient is:
Q / 3 C v 2
PD st =
P
Note: A minimum supply pressure to the terminal equipment is required for Equation 11. If
you do not specify a valve for this input field, the default value will be assumed.
Terminal equipment definitions for domestic hot and cold water use the data categories shown
in Fig. 1-42. The supply code for flush valve is VALVE and for flush tanks, TANK. If you use these
codes, then the quantity of fixture units for the valve or tank is converted into flow GPM
according to Fig. 1-43. For other fixture types, you can estimate the terminal flow GPM. Supply
pressure must account for the minimum pressure and pipe size connection for the fixture.
Gas Appliances
Fig. 1-44 shows the approximate gas demand for common appliances. These default values were
obtained from the ASPE Data Book, Vol. 1, Fundamentals of Plumbing Design, 1983-1984, p. 6-8.
The heating value of the gas is used to convert the Btu/hr value into cu ft/hr flow of gas.
Appliance Output
Btu/hr
Commercial kitchen equipment:
Small broiler 30,000
Large broiler 60,000
Combination broiler and roaster 66,000
Coffee maker, 3-burner 18,000
Coffee maker, 4-burner 24,000
Deep fat fryer, 45 lbs of fat 50,000
Deep fat fryer, 75 lbs of fat 75,000
Doughnut fryer, 200 lbs of fat 72,000
2-deck baking and roasting oven 100,000
3-deck baking oven 96,000
Revolving oven, 4 or 5 trays 210,000
Range with hot top and oven 90,000
Range with hot top 45,000
Range with fry top and oven 100,000 Fig. 1-44: Common Appliances:
Range with fry top 50,000 Approximate Gas Demand
Coffee urn, single, 5 gallon 28,000 (reproduced with permission from ASPE
Data Book, Vol. 1, p. 3-8.)
Coffee urn, twin, 10 gallon 56,000
Coffee urn, twin, 15 gallon 84,000
Residential equipment:
Clothes dryer 35,000
Range 65,000
Stove top burners 40,000
Oven 25,000
30-gallon water heater 30,000
40- to 50-gallon water heater 50,000
Log lighter 25,000
Barbecue 50,000
Miscellaneous equipment:
Commercial log lighter 50,000
Bunsen burner 3,000
Gas engine, per horsepower 10,000
Steam boiler, per horsepower 50,000
Thermal Analysis
The heat gain/loss and temperature calculation options apply to liquids and steam only.
You can choose between two options for determining the fluid temperature in each pipe section.
In the first option, you can assume an average supply and return fluid temperature for all supply
and return sections. This data is used to calculate the fluid properties. An example of the use of
average temperatures is 200 oF supply and 160 oF return for a hot water heating system.
In the case of un-insulated pipes and high temperature steam and hot water, the supply
temperature at each terminal must be calculated. This is done by calculating the entering and
leaving temperature of each supply section, beginning with the initial temperature of the first
section. The first section must be identified. In the case of liquids, the first section is the section
downstream of the pump station.
The entering temperature of any supply section is the leaving temperature of the upstream
section. You can reset the leaving section temperature for sections that have primary
equipment.
The following equations are used to calculate liquid and steam heat gains and losses:
T avg - T amb
Qs =
Ro Rs
R s log e R s log e
Ri + Ro + 1 / h
K1 K2
where Qs = rate of heat transfer per square foot of outer surface (Btu/hr sq ft)
Tavg = average temperature of section (F)
Tamb = temperature of ambient air (F)
Ri = inside radius of pipe, (in.)
Ro = outside radius of pipe, (in.)
Rs = outside radius of insulation (in.) - Ro + insulation thickness
K1 = thermal conductivity of pipe (Btu in./hr sq ft F)
K2 = thermal conductivity of insulation (Btu in./hr sq ft F)
1/h = outside surface resistance (hr sq ft F/Btu in. = 0.6)
Q s = q s As
where Qs = total rate of heat transfer from pipe section (Btu/hr)
As = outside surface area of pipe (sq ft)
The temperature of the liquid flowing through the pipe section is obtained from Equation 14.
The procedure for determining steam temperature changes is described in Steam Piping.
Q s (Btu / hr)
dT s =
gal. cu ft min . lb btu
Fs 0.13368 x 60 x Df xCp lb F
min . gal. hr cu ft
Tl=Te - d Ts
where Tl = temperature of fluid leaving section (F)
Te = temperature of fluid entering section (F)
T l +T e
T avg =
2
The average temperature Tavg in Equation 12 depends on the leaving section temperature in
Equation 16. The procedure consists of initializing the leaving temperature to the entering
section temperature and then iterating through Equations 12 through 16 until a steady state
value of Tavg occurs.
Pipe Sizing
The general principles of pipe sizing are described in the ASHRAE Handbook: 1985 Fundamentals,
Chapter 34, p. 34.1. The Darcy-Weisbach and Colebrook-White equations are used to calculate
the pressure drop in a pipe section due to fluid friction. The Darcy-Weisbach equation is:
L V2
h= f 2 g
D
where h = head loss due to friction (ft)
f = friction factor, dimensionless
D = inside diameter of pipe (ft)
L = length of pipe section (ft)
V = average velocity (ft/sec)
g = acceleration of gravity (ft/sec2)
The friction factor f is a function of the pipe roughness , inside diameter D and a dimensionless
parameter, the Reynolds number.
Dv
R e=
where = fluid density at given temperature (lb/cu ft)
= dynamic viscosity of fluid (lb/ft sec)
Laminar flow exists where Re < 2100. For this condition, the friction factor f is obtained from:
64
f=
Re
Where Re > 2100, the flow is assumed to be turbulent. The Moody diagram that relates the
friction factor f with Reynolds number and the relative roughness /D is shown in ASHRAE
Handbook: 1985 Fundamentals, p. 2.10, fig. 13. The Colebrook-White equation for turbulent
flow, shown in Equation 20, is used for the friction factor f.
1 9.3
= 1.14 + 2 log 10 (D / ) - 2 log 10 1 +
f R e ( / D ) f
For fully rough flow, the value of Reynolds number is high and the last term in Equation 20 can
be neglected. Equation 21 can be used in its place.
1 D
= 1.14 + 2 log10
f
Equation 20 is used to calculate the friction factor f for turbulent flow. The Newton-Raphson
iterative method is used to solve for f since f appears on both sides of the equation. The initial
value of f for this iteration is obtained from Equation 21. As Reynolds number increases, the
values from Equation 20 approach those that would be obtained by applying Equation 21 directly
for fully rough flow.
Pipe sizing and the size of each pipe section depend on your criteria (See Sizing Criteria in this
engineering basis). The criteria can be based on the limits for pressure loss per 100 ft, maximum
velocity or maximum flow. The sizing iteration consists of comparing the pressure drop/100 ft,
velocity or flow against the limits you specify. This is done for each standard pipe size, beginning
with the smallest size and continuing until a size is found that meets the criteria. When the
maximum pipe size limit is reached, you must use your engineering judgement to decide whether
to:
maintain the sizing criteria and increase the pipe size above the maximum limit or
maintain the pipe size limit and calculate the new criteria for this size.
Steam Piping
Steam distribution network pipe sizing requires flow rates and sizing criteria for the pipe
sections. The flow rate for dry steam or steam with a small amount of water (condensate) is in
accordance with the laws of fluid flow. The flow is a function of these properties:
Steam
Pipe
temperature
length
pressure
diameter
viscosity
pressure drop
density
The Darcy-Weisbach and Colebrook-White equations (Equations 17 through 21) are used to size
steam pipes,. These equations are described in Pipe Sizing.
The flow of steam is automatically induced by the volume shrinkage that occurs when steam
gives up its latent heat and condenses. Therefore, steam flow involves the analysis of two-phase
flow. Condensate flows in the same direction as steam and must be trapped at intervals along
the pipe length. Typical pressure classifications of steam in HVAC applications include
The basis of pressure classification is the initial pressure. Default values are shown in Fig. 1-45.
In addition to selecting a pressure classification, you can specify additional sizing criteria and
constraints for the project including
The maximum system pressure drop criterion is met by successively reducing the sizes of pipe
sections for circuits that exceed the limit. This procedure is described in Circuit Balancing in this
engineering basis.
Pipe sizing iteration consists of checking the pressure drop/100 ft and the maximum velocity of
each standard pipe size of a given pipe material against your sizing criteria. This sequence begins
with the smallest pipe size and continues until the required size is found or the maximum pipe
size limit for the given material is reached.
The general laws of gas flow can be used in sizing steam pipes. This assumes that the steam
temperature and pressure maintains the steam quality above its saturation level (gas) and the
small amount of condensate in the system flows in the same direction as the steam.
In the program, you can enter graphic and text input to a steam supply system and its
condensate return system simultaneously since they serve the same terminal equipment. The
two systems are analyzed separately. Flow quantities for the terminal equipment are not
automatically transferred from steam supply to condensate return since the quality of steam
downstream of the terminal equipment depends on the equipment type, heat losses, pressure
losses, steam traps, sub-cooling, and other design factors.
Return systems are described in Steam Condensate Return Piping in this engineering basis.
The changes in steam conditions for a section are due to heat loss and pressure loss. For a given
section,
P1, V1 and T1 are set equal to the corresponding leaving conditions in the upstream section. The
pressure loss dP is calculated using your sizing criteria. The leaving pressure is calculated using
the equation:
P 2 = P 1 - dP
The amount of steam condensed in the pipe depends on dQ (heat loss) and dP (pressure loss).
Each of these factors by itself produces condensate. Condensation results in an increase in the
specific volume (expansion).
To find the temperature and specific volume due to pressure losses, you should assume
polytropic expansion.
n -1
P2 n
T 2= T1
P1
1
P1 n
V 2 =V 1
P2
If the specific volume V2 is less than the specific volume Vs2 of saturated steam at pressure P2,
then the steam is wet and the dryness fraction q2, due to the pressure drop only, is the ratio
V2/Vs2. The volume of liquid can be neglected.
d Q=d U + d W
where dQ = heat gained (+ve) or lost (-ve) (Btu/hr/lbm)
dU = change in internal energy
dW = work done in moving from state 1 (entry) to state 2 (exit) dQ, dU and dW
in heat units
n P 1 V 1 - P 2 V 2
d Q = H 2 - H 1 +
J (n - 1)
Equation 26 is based on the general expansion and compression law for gasses (PVn = Constant).
The only unknown quantity in the equation is the enthalpy change (H2 - H1).
n P 1 V 1 - P 2 V 2
H 2= H1+d Q -
J (n - 1)
The dryness fraction of steam at the exit point 2 due to pressure loss and heat loss can be
calculated from
H 2 = h f 2 + x2 h f g 2
H2-hf 2
x2 =
hf g2
The steam that condenses when it moves from entry point 1 to exit point 2 is calculated from
C 2 = 1 - x2 M 1
where C2 = condensate (lbm/hr)
M1 = mass flow of steam at entry (lbm/hr)
The procedure assumes that the condensate at the exit point 2 of the pipe section is trapped and
removed from the system. The quantity of steam remaining at point 2 is now the quantity
entering the next section or sections (junction).
If point 2 is a junction, then the remaining quantity of steam is divided between the downstream
sections in proportion to the original required flow of steam through those sections.
Definitions
Wet Return Systems: The return pipe contains only the liquid. There is no flash vapor. This can
occur when the condensate entering the trap is sufficiently subcooled. It can also occur when
the liquid and vapor are separated and the wet return line is kept below the boiler water so that
only liquid can flow through the line.
Dry Return Systems: The condensate piping contains both saturated liquid and saturated vapor.
This is typical of most condensate return systems.
Open Return Systems: The system can be wet or dry. It is vented to the atmosphere and the
condensate line is essentially at atmospheric pressure. The driving force for returning
condensate is gravitational acceleration and the return line is sloped.
Closed Return Systems: The pressure in the condensate return line is above or below
atmospheric pressure and is not vented to the atmosphere. The driving force for returning the
condensate is pressure loss along the return line.
Condensate return types can be wet or dry and the system type can be open or closed. Wet
types refer to liquid only and dry types are for vapor only. Given the flow rate and sizing criteria,
the pipe sizes can be determined using the methods described below.
Sizing Methods
Wet Closed Return: The Darcy-Weisbach and Colebrook-White equations are used to size the
pipe. The sizing criterion is pressure drop per 100 ft. or maximum velocity. Equation 31 is the
Darcy-Weisbach equation modified for steam condensate return.
f L V2
P= x x x
144 D g c 2
Typical design pressure losses per unit length (P/L) are in the range of 1/16 psi to 1 psi per 100
ft. The velocity for liquid condensate systems should not exceed 150 ft/min. For vapor systems,
the velocity should not exceed 7000 ft/min. The friction factor f is calculated from the
Colebrook-White equation as described in Pipe Sizing in this engineering basis.
Wet Open Return: The pipe is assumed to be filled with liquid. Sizing is based on an equivalency
between horizontal pipe flows and sloped pipe flow as shown in Fig. 1-47. The system is vented
and flow is gravitational.
Pipe Slope 5
0.5 1.0 1.5 2 3 4
in. / 10 ft
Pressure Drop 1.805
0.18 0.361 0.540 0.722 1.084 1.44
psi / 100 ft
Fig. 1-47 illustrates that for increasing pipe slopes, the pressure drop/100 ft criterion also
increases and you end up with a successively smaller pipe.
Dry Open Return: This method is the same as wet open return. The fluid is assumed to be vapor.
The pipe slope is assumed to be 1 in. per 10 ft and the pressure drop/ 100 ft criterion is set at
0.361 psi. The system is vented and the flow is gravitational.
Fig. 1-48, Fig. 1-49 and Fig. 1-50 are reproduced with permission from ASHRAE Handbook: 1985
Fundamentals, Table 19, p. 34.16. For sizes and pressure losses marked a, the velocity is above
7000 ft/min.
Dry Closed Return: The condensate is assumed to be vapor. Typically, the volume fraction of
vapor in the condensate is between 0.96 and 0.99. The pipe is sized from Fig. 1-48, Fig. 1-49, and
Fig. 1-50, knowing the pressure drop criteria (psi/100 ft), initial supply pressure (PSIG), design
return pressure (PSIG), and amount of condensate flow in the pipe section.
Supply Pressure 50 PSIG Supply Pressure 100 PSIG Supply Pressure 150 PSIG
Return Pressure 0 PSIG Return Pressure 0 PSIG Return Pressure = 0 PSIG
Psi/100
1/16 1/4 1 1/16 1/4 1 1/16 1/4 1
’
Diam.
½ 42 92 200 28 62 133 23 51 109
¾ 91 200 420 62 134 290 50 110 230
1 180 380 800 120 260 544 100 210 450
1 1/4 370 800 1680 250 540 1130 200 440 930
1 1/2 560 1200 2520 380 810 1700 310 660 1400
2 1110 2350 a 750 1590 a 610 1300 a
2 1/2 1780 3780 a 1200 2550 a 980 2100 a
3 3190 6730 a 2160 4550 a 1760 3710 a
4 6660 13,800 a 4460 9340 a 3640 7630 a
6 19,600 a a 13,200 a a 10,800 a a
8 40,500 a a 27,400 a a 22,400 a a
Gas Piping
To size fuel gas piping, you need to supply specific data such as:
Diversity in each section is an important factor in determining the correct gas pipe size.
The sizing procedure consists of a preliminary analysis to determine the longest circuit. The
longest circuit is usually the circuit with the longest length of piping but is also dependent on the
number of valves and fittings in the circuit. You need to add equivalent lengths of fittings and
valves to obtain the longest equivalent circuit length. This is the only distance used to determine
the sizes of all pipe sections in the network.
The flow capacities for various standard pipe sizes and for the longest circuit length are based on
these equations:
0.5
h
Q = 3550 x K
S x L
For gas pressure exceeding 1 PSIG and pipes sizes smaller than 6 in.
0.5
P x a
Q = 4830 x K
S x L
0.5
D
5
K=
3.6
1 + + 0.03 x D
D
Equations 32, 33 and 34 can be applied to all types of fuel gases provided by the gas utility
industry. This includes both natural and manufactured gas. To size pipes for a particular type of
fuel gas, use the specific gravity of that gas. Specific gravities for typical fuel gases include 0.67
for natural gas, 0.42 for coal gas, 0.86 for producer gas from bituminous coal, 0.47 for oil gas, and
0.55 for methane. Refer to Flow of Fluids, Crane, p. A-8 for specific gravities of other gases.
For gas pressures exceeding 1 PSIG and pipe sizes equal to or larger than 6 in.
0.5394
P 12 - P 22
Q = 36.8 x E x D 2.6182
Lm
where E = efficiency factor
= 0.92 for average operating conditions
P1 = pressure entering pipe network (psi)
P2 = pressure leaving pipe network (psi)
Lm = length of pipe circuit (miles)
Sizing procedures consist of generating a table of flow rates Q for each inside pipe diameter D for
a given maximum circuit pressure drop h. The initial trial length L is the measured length of the
longest circuit. The size of each pipe section is selected from the table of flows in the section.
Dynamic Head
add the pressure losses in each section of the circuit to obtain the circuit pressure loss
determine the highest circuit pressure loss
set the entering pressure of the first section in the circuit as the highest circuit loss
analyze each section in the circuit starting with the first section and moving through
each section in the fluid flow sequence
the entering section pressure is the leaving section pressure of the upstream
section
the leaving section pressure is the entering section pressure less the section loss
calculate the balancing required in each circuit. This is equal to the highest circuit
pressure loss minus the given circuit pressure loss.
In the case of primary-secondary systems, the primary circuit ends at the booster pump on the
terminal equipment if there is no booster pump in the circuit.
Secondary systems are analyzed independently as separate systems. The entering pressure of
the first section in the secondary system is the pressure loss of the secondary circuit with the
highest pressure loss.
Static Head
Static head calculations apply to liquids only. The static head at any point in the piping system is
due to the weight of the column of liquid above that point.
The static heads at the start and end nodes of each pipe section in the piping system is
estimated. The static head at any node is the difference between the highest z coordinate of all
the nodes in the system and the z coordinate of the given node.
Circuit Balancing
1. Balancing to maintain a maximum limit for circuit pressure loss. This option applies to
steam systems only.
2. Balancing to minimize the amount of throttling in the circuit. This option applies to
liquid supply systems only.
The limiting criteria used in the balancing procedure is the minimum velocity limit for each
nominal pipe size. The iteration procedure is:
2. Sort the circuits in ascending order of pressure loss and find the circuit with the highest
pressure loss.
3. If the highest circuit pressure loss is less than the maximum allowed, exit the iteration
routine.
4. Calculate the pressure loss reduction required in the circuit with the highest pressure
loss (circuit pressure loss ─ maximum allowed).
5. Move through the circuit in sequence from the last section with terminal equipment to
the first supply section.
a. If the given section has an override size, proceed to the next upstream section.
c. Calculate new pressure loss in this section and the pressure reduction in the circuit.
d. If required circuit pressure reduction is not satisfied, repeat steps 5b and 5c until
upstream section size or minimum velocity is reached.
e. When upstream section size is reached, repeat steps 5a through 5d for the next
upstream section until the first section is reached.
f. For the first section, repeat steps 5a through 5c until the required circuit reduction
is satisfied or the minimum velocity is reached.
6. Check if all the sections have reached minimum velocity (ignore override sizes). If so,
exit the iteration routine.
7. If maximum allowable circuit pressure loss is still not satisfied, start again with step 1.
The limiting criteria used in this procedure are your design criteria for maximum velocity in the
piping system. The iteration procedure is:
2. Sort the circuits in ascending order of pressure loss and find the circuits with the highest
and lowest pressure loss.
3. If the circuit flag of the circuit with the lowest pressure loss indicates that the current
loss cannot be further increased, exit the iteration routine.
4. Calculate the pressure loss increase required in the circuit with the lowest pressure loss
(highest circuit pressure loss ─ lowest circuit pressure loss).
5. If the pressure loss increase from step 4 is less than or equal to 0, exit the iteration
routine.
6. Move through the circuit with the lowest pressure loss, in sequence, from the last
section with the terminal equipment to the first supply section.
a. If the given section has an override size, go to the next upstream section.
b. If the section flag indicates that the section has reached maximum velocity, then go
to the next upstream section.
e. Calculate the new velocity and pressure loss in the section followed by the increase
in circuit pressure loss.
f. If the new velocity in the section is greater than the maximum velocity, then
g. If the required circuit pressure increase is not satisfied, then repeat steps 6d
through 6f until the first section is analyzed.
7. Set circuit flag indicating that the circuit has been analyzed and the circuit loss cannot
be increased any further.
Go to step 1.
Pressurization Tanks
Pressurization (expansion/compression) tank sizing is based on the methods described in the
1987 ASHRAE Handbook, pp. 13.11 - 13.15. Pressurization tanks include
Open
Closed
Such tanks are appropriate for system types that use condenser water, chilled water, hot water,
domestic hot and cold water, glycol and brine. High-temperature hot water systems can be
designed up to operating temperatures of 280 F as stated in Equation 40.
Pressurization tank size is based on the volume capacity of the system. System volume is
estimated in three parts:
The volume of all the pipe sections in the system. The pipe volume is converted into gallons
of liquid using the density of the liquid. The liquid temperature for determining the
density is the lowest temperature in the system.
The liquid storage capacity of all the equipment in the system. The volume storage capacity
of the terminal equipment, primary equipment and miscellaneous equipment.
The tank volume size in gallons is estimated as a percentage of the total system volume The
minimum recommended volume is 6% in accordance with the 1987 ASHRAE Handbook.
As an alternative to sizing the tank based on the percentage of system volume, you can use the
system liquid expansion volume which is the difference in volumes at the maximum temperature
of the piping system and at the minimum temperature.
Fill Pressure: The tank location with respect to the piping system affects the initial fill or
minimum pressure Pf at the tank. The tank can be at three possible locations with respect to the
system.
P f =V + F + A
P f =V + H + A
P f = V + PH + A
where PH = pump head (ft of liquid) that must be added to maintain the positive pressure
at the top of the system
In all three cases, the atmospheric pressure A is added to obtain absolute pressure You must
specify either the initial fill pressure Pf or the system static head H.
E
Vt=
P a P a
-
P f Po
0.041 x T - 0.0466 x V s
Vt=
P a P a
P f P o
0.041 x T - 0.0466 x V s
Vt=
P f
1
P o
Tank sizing for chilled water systems using Equation 39 will result in tanks of very small size
because of the low pressurization coefficients (40 to 90F temperature range). For that reason,
closed compression tanks applied to chilled water systems are sized as follows:
Regular tank size is half the equivalent hot water size. The piping system is considered to be
operating from 70 F to 200 F. Diaphragm tank size is calculated from
eV s
Vt=
P f
1 -
Po
The lowest temperature of chilled water equals the minimum design temperature. This can be
assumed to be 35 oF. The highest temperature is the highest anticipated ambient temperature
The net pressurization factor e is obtained from Fig. 1-51.
Highest Pressurization
Temp. F Factor
90 0.0041 1-51: Net Expansion Factor:
100 0.0058 Water in Chilled Water Systems
110 0.0077
120 0.0100 (reproduced with permission from 1987 ASHRAE
130 0.0124 Handbook, Table 2, p. 13.15)
140 0.0150
150 0.0179
160 0.0209
System data
Flow and head
Domestic water flow based on total fixture units
Primary system curve of flow vs. head in tabular form
The total static head (TSH) is calculated given the discharge head and suction lift or suction head.
NPSHA is calculated for open systems such as condenser/cooling tower systems where the water
is in contact with the atmosphere, and for high temperature hot water (HTHW) systems.
In the case of open systems NPSHA is affected by the total static head. For HTHW, NPSHA is
affected by high values of vapor pressure.
NPSHA has limited usage in closed piping systems, which include water, glycol and brine. For a
detailed explanation, refer to Pump & System Curve Data, Bell & Gossett, p. 11.
Net Positive Suction Head (NPSH) can be defined as the head that causes liquid to flow
through the suction piping and into the eye of the impeller. This head is due to either
the pressure of the atmosphere or static head plus atmospheric pressure.
Required NPSH (NPSHR) is a function of the pump design. It varies among different pump
manufacturers, between different pumps from the same manufacturer and with the
capacity and speed of any one pump. The manufacturer supplies this quantity for the
pump.
Available NPSH (NPSHA) is a function of the piping system which includes the pump. This is
calculated based on the z-elevations of the liquid and piping system. The available
NPSH must be equal to or greater than the required NPSH of the pump.
Vapor pressure data for the given liquid and given temperature is obtained from Fig. 1-53.
Default values for water from 60 oF to 450 oF and for diesel oil and gasoline from 0 oF to 150 oF
are shown. The frictional losses on the suction side of the pump must be calculated as required
for the NPSHA equation.
System Data
System head includes the highest circuit pressure drop in the system. It is the sum of all the
pressure losses of all the sections in the circuit. Section-by-section pressure losses are calculated
in both psi and feet of liquid at the entering section temperature and density of the liquid.
Circuit pressure losses are obtained by summing the section losses in psi and then expressed in
feet of liquid if required. This is because losses measured in feet of liquid are dependent on the
density of the liquid at different temperatures.
Equation 43 applies to closed systems. For open systems, the total static head in psi is
added to the pressure head
H o = H c + TSH
Calculations for TSH are shown in Total Static Head for Open Systems. The system head in psi is
converted to feet of liquid at the temperature of the liquid in the pump discharge pipe section.
H 1 = H 144 / D
where H1 = system head (ft of liquid)
H = Hc for closed systems, or Ho for open systems
D = density of liquid at pump discharge section temperature (lb/cu ft)
The static heads are the z axis distances from the lowest and highest point of the piping system
to the primary pumping station. System flow Q1 is calculated as the flow in the discharge section
of the pump station. In the case of domestic water, the flow at the pump or first section, is
calculated on the basis of total fixture units, if fixture type data is entered as terminal flow.
System Curve
The primary system curve showing flow versus head is calculated from this equation:
2
Q1
H 2 = H 1
Q 2
H2 and Q2 are points on the system curve generated by varying the value of Q2. The flow vs.
head table calculates 30 points. The intervals for Q2 are obtained by dividing the system flow Q1
by 20. The table, therefore, includes 10 points above the required system operating point of Q1,
H1.Fig. 1-54 shows system curve construction using a table generated by Equation 46.
Fig. 1-54:
The primary pumping station can be any configuration of pumps in series and parallel. All pumps
in a pumping station are assumed to be identical.
The flow through each pump is the system flow divided by the number of parallel pump flow
paths at the station.
The head for each pump is the system head divided by the number of pumps in series in any
parallel path. All parallel paths should have the same number of pumps in series.
Brake horsepower and motor horsepower are calculated from the following equations.
GPM H SPGR
BHP =
PE
3960 1 +
100
BHP
MHP =
ME
1+
100
Standard motor horsepower is obtained from Fig. 1-55. It is the nearest size above MHP.
0.16 5 50
0.25 7.5 60 Fig. 1-55: Standard Motor Sizes
(reproduced with permission from ASHRAE
0.33 10 75
Handbook: 1985 Fundamentals, Table 24,
0.50 15 100 p. 26.25)
1 25 150
2 30 200
3 40 250
The flow through the booster pump is the flow through the section with the booster pump.
The booster pump head is the highest circuit pressure drop in the secondary system of circuits
downstream of the given booster pump.
Brake horsepower, motor horsepower and standard motor size are calculated in the same way as
primary pumps.
This section is based upon information and procedures described in the following technical
bulletins:
1. Parallel and Series Pump Application, Bell & Gossett Bulletin No. TEH-1065,
International Telephone and Telegraph Corporation, Morton Grove, 1965.
2. Pump & System Curve Data for Centrifugal Pump Selection and Application, Bell &
Gossett Bulletin No. TEH-375, International Telephone and Telegraph Corporation,
Morton Grove, 1967.
The results of pump performance tests are shown by means of a plotted curve that relates the
flow (gpm) to the pressure head produced (ft of liquid). The manufacturer establishes the pump
curve. A typical head capacity curve is shown in Fig. 1-56.
Flow
Point Head (ft) Effic. (%)
GPM
1 800.00 234.00 58.00
2 1000.00 203.00 60.00 Fig. 1-57:
Pump Test Performance Data:
3 1500.00 192.00 77.00
Pump Curve
4 2000.00 180.00 87.00
5 2500.00 167.00 89.00
6 3000.00 152.00 84.00
Pump curve (plotted test data) is based on the impeller diameter and pump rpm. From this test
data, the pump equations, piping methods and fluid dynamics can be used to estimate pump
performance for other pump speeds (rpm) and impeller diameters (in.). This includes:
Pump affinity laws, as published in Pump & System Curve Data, p. 6, is used to calculate the
effects of changes in impeller diameters and rotational speeds on the pump curve. These laws
state that
1. Pump gpm capacity varies directly as the speed (rpm) or impeller diameter ratio.
2. Pump head varies directly as the square of the speed (rpm) or impeller ratio.
You can use the pump station and booster pump master or override forms to request a specific
pump performance curve from the library. These curves are based on test impeller diameter and
rpm speed. The actual pump performance curve data is calculated from the pump test curve
data that you specify, and your input for impeller diameter (in.) and speed (rpm), using the pump
affinity laws.
In Fig. 1-58, the terms Q1 H1 and R1 refer to the test data values in the library. The terms Q2 H2
and R2 refer to your input on the pump station or booster pump master or override form. The
new curve results are presented in tabular form.
Parallel Pumping
All pumps in the primary pumping station should be identical in size and type. The effect of
pumps in parallel is to divide the total system flow equally among the number of parallel pump
paths.
Fig. 1-59 is a schematic layout of pumps in parallel. The check valves at the pump discharge are
essential to prevent any short-circuit flow or pump damage when a single pump is running. Fig.
1-60 is a graphic representation of parallel pump curve construction.
Series Pumping
All pumps in the primary pumping station are assumed to be identical. The effect of pumps in
series is to divide the total system head equally among the number of pumps in series in any one
of the parallel pump paths. Pump curve points for pumps in series are calculated by multiplying
the head at each point by the number of pumps in series in any one of the parallel paths. The
flow remains the same through each pump in series. Fig. 1-61 is a schematic layout of pumps in
series. Fig. 1-62 is a practical installation of pumps in series where the pumps can be run singly
or simultaneously. Fig. 1-63 is a graphic representation of series pump curve construction.
Fig. 1-64 shows a primary pumping station consisting of a combination of pumps in parallel and
series. The pumps are assumed to be identical. The flow through each pump is the total system
flow divided by the number of parallel paths in the station. The head for each pump is the total
system head divided by the number of pumps in series in any one parallel path. Pump curve
points for the combination are calculated using the test data for a single pump.
Point of Operation
The point of operation of the pump on the combination of parallel and series pumps is the
intersection of the system curve described in Fig. 1-54 and the pump curve on the combined
pumping station curve. This is shown in Fig. 1-65.
Domestic hot and cold water distribution systems are analyzed as open network, liquid supply
systems. Use the system code DHW or DCW. The reference libraries used by domestic water
systems include:
Pipe material properties. The library includes steel, cast iron, copper, and plastic pipe
materials, as shown in Fig. 1-23 through Fig. 1-28.
Frictional loss correction factors due to pipe age, as shown in Fig. 1-29.
System cross-checking tables for pipe materials and insulation, as shown in Fig. 1-32 and
Fig. 1-33.
Sizing criteria based on pressure drop per unit length, velocity or flow for each nominal pipe
size, as shown in Fig. 1-34.
Flow rate for each fixture is entered using the deftermequip form or ovrtermequip form. The
flow at the fixture can be specified as a flow rate in gpm or as a fixture type. A fixture type refers
to a corresponding set of design data in the reference library, as shown in Fig. 1-42. The design
data consists of:
Minimum Pressure:
The minimum pressure required at the fixture. The primary pump static head is
calculated to maintain this pressure. If a pump is not specified and the water main
pressure is used, you must choose the circuit balancing analysis option to maintain the
minimum pressure at the fixture and not exceed the water main pressure.
The total fixture unit data is used to calculate the flow rate in the main section. If a
diversity factor applies to the main section, then first calculate the flow based on the
sum of all total fixture units in the system, then multiply this flow by that diversity
factor.
The remaining system analysis and design procedures are described in earlier sections of this
engineering basis and are summarized below.
A flow rate is assigned to all sections in the network based on the required flow rate at the
fixtures. See Network Analysis.
Pipe sizing options can be based on pressure drop per unit length, velocity or maximum
flow. See Sizing Criteria.
The Colebrook-White and Darcy-Weisbach equations are used to calculate the pressure
losses through pipe sections. See Pipe Sizing.
Fitting and valve loss calculations can be based on velocity pressure factors, K, or equivalent
lengths, L/D. See Fittings and Valves.
Heat gains and losses and temperature changes in the system are based on the thermal
data that you can specify in the input forms. See Thermal Analysis.
Static and dynamic heads are calculated for all nodes in the pipe network. See Circuit
Pressure Analysis.
The system can be designed to provide the minimum pressure required at fixtures and
maintain the maximum pressure limit at the water main. See Circuit Balancing.
The primary pump station is analyzed if a primary pump is used to develop the pressure in
the main pipe section. See Pump Performance Based on System Requirements.
Booster pumps can be located in any supply pipe circuit to increase the pressure in the
circuit. See Network Analysis.
Pressurization tanks can be located on the discharge side of the pump, on the suction side
of the pump, or at the high point of the pipe system. See Pressurization Tanks.
Sanitary Drainage and Venting
The design of the sanitary drainage system is based on the fixture unit method. The reference
library includes a series of look-up tables and corresponding data forms you can use to specify
the data in accordance with a specific geographic location or municipal code you may need to
follow. The table format was designed to accommodate various city codes throughout the
United States. It should be flexible enough to allow any adjustments you make.
The sanitary drainage library tables, shown in Fig. 1-66 through Fig. 1-69, are:
The horizontal pipes, or branches, on each floor connected to a vertical stack are sized first.
The fixture types associated with each horizontal branch are converted into fixture units.
Fixture units handled by each pipe segment in the horizontal branch are calculated
sequentially, starting with the last fixture and working toward the vertical stack.
The pipe size for the number of fixtures is chosen using the reference library data, as shown
in Fig. 1-67.
The number of fixture units in each pipe segment in the vertical stack are calculated
sequentially, starting at the highest horizontal branch.
The pipe size is determined using the values indicated in Fig. 1-67 for stacks with three or
fewer branches, or for stacks with more than three branch intervals, as appropriate.
If the resulting pipe size for a vertical segment is smaller than that of the horizontal branch
above it, the pipe size for the vertical segment is adjusted to match that of the
horizontal branch.
The pipe size for the horizontal building drains connecting the vertical stacks is based on the
slope, the fixture units handled by each pipe segment between vertical stacks, and by
the corresponding column shown in Fig. 1-66.
Sizing Procedure
Sanitary vent systems must be developed within the same graphic model as the associated
sanitary drainage system, toggling back and forth between the two system types as necessary.
First analyze the drainage system to obtain the drainage pipe sizes, then size the associated vent
system.
Sanitary vent sizing uses the reference library look-up tables as shown in Fig. 1-68 and Fig. 1-69
Determine the length of the vent pipe from its point of connection to the drainage system to the
point of vent exit. In order to use the library look-up tables, obtain the pipe size and number of
fixture units at the point of connection, which is typically at the low point of the sanitary
drainage vertical stack.
To size vent pipes connected to a drainage stack, read from the table in Fig. 1-69, the vertical
vent stack size that corresponds to the vent pipe length, and the drainage stack diameter and
fixture units that was determined from drainage pipe sizing.
To size vent pipes connected to a horizontal drainage branch, the slope for that horizontal drain
is required. The size can be read from the table shown in Fig. 1-68. Vent piping section types
include:
extensions
terminal
header
individual
branch
circuit
relief
The same sizing procedure can be used for all vent types, with the exception of the relief vent.
Relief vents use the same sizing table as horizontal vent pipes, with the drainage pipe slope as
specified in the master or override form. The vent length, however, is calculated from the point
of connection to the sanitary drainage stack to the point of connection to the vertical vent stack.
Storm Drainage
The design of the storm drainage system is based on the look-up table method. The reference
library includes a series of look-up tables and corresponding data forms you can use to specify
the data in accordance with a specific geographic location or municipal code that you may need
to follow. The table format was designed to accommodate various city codes throughout the
United States. It should be flexible enough to allow any adjustments you make.
The tables can be used to design continuous flow storm drainage systems. To design controlled
flow systems, you will need to enter the equivalent total area per drain and rainfall rate for
continuous flow.
The drain in the storm system sizing corresponds to the terminal equipment in other system
types. Gutter sizing is not included in the program and storm systems that include gutters must
be modified to convert the system into an equivalent system of roof drains, leaders and
horizontal rainwater pipes.
The storm drainage library tables, shown in Fig. 1-70 and Fig. 1-71, are:
roof drain and leader sizing
horizontal rainwater pipe sizing
For each valid slope and rainfall rate, you can define the nominal pipe size and the area that can
be drained. The area is in square feet.
Sizing Procedure
For storm drainage, use the input forms and place the appropriate engineering elements to
specify:
The rainfall rate for the building type and location, as determined by code requirements or
other design considerations.
The locations of roof drains, and their associated roof and washdown areas if those areas
are different from the master values.
Orientations for vertical leader pipes and horizontal pipes are determined from the graphic
data.
Vertical leaders are sized using the reference library as shown in Fig. 1-70.
Horizontal pipe sizes are based on your input slope, and the maximum rainfall rate and
drainage area of the drains connected to that pipe. The reference library, as shown in
Fig. 1-71, is used.
If the rainfall rate is greater than the maximum in that library, an error message is
generated and the maximum rate is used. For any other case, actual rates are rounded
up to the nearest rate in the library if necessary.
The vertical leader size from the library is checked against the size of the horizontal pipes, if
any, connected above it. If the leader is smaller, the size is adjusted to match that of
the horizontal pipe.
Similarly, the horizontal pipe size from the library is checked against the size of the vertical
leader, if any, connected above it. If the horizontal pipe is smaller, the size is adjusted
to match that of the vertical leader.
Material Estimating
Pipe material, insulation, fittings, valves and equipment quantities for each pipe section in
the system
Total pipe lengths for each pipe material and pipe size used in the system
Total insulation surface areas for each insulation type and thickness used in the system
Fitting quantities for each fitting type and size used in the system
Valve quantities for each valve type and size used in the system
Turn to Appendix Two: Reports for more information on material estimation reports.